Feature
FeatureTechnologies Offering
Offering Value
Value inin New
New Fields
FieldsTechnologies

1944
1944
(FormerMidorigaoka
UedaKita
KitaWorks
Works (Former
MidorigaokaWorks)
Works)
Ueda

44

NovemberNovember
2017
2017

COLUMN
Cover image:

Ueda Kita Works (Former Midorigaoka Works)
1944

Sanyo Shokai Special Electric Works (later Tokyo Works), established in June 1932,
had continuously expanded its production capacity, eventually stretching it to the limit.
This led to the decision to construct a new factory in a suburban region. Therefore, we
acquired the land in the northern part of Ueda, Nagano Prefecture, and established "Ueda
Kita Works" (later Midorigaoka Works) in February 1944.
However, as the war intensified, it grew increasingly difficult to acquire raw materials.
Beginning with simply finding lumber, we overcame many hardships and managed tobuild a new factory.
Immediately after its completion, the factory started operations as an exclusive factory
for the Army Aviation Headquarters. We primarily manufactured power converters foraircraft radios and engine starter generators.
At the time, we mainly produced small-sized power supplies, but after the war, shiftedto larger power products including 500 VA to 5 kVA generators for ship radio power
units. As those demands continued to grow, by the 1950s, our company was widely
known in the radio device industry as a manufacturer with top-level technology.
Midorigaoka Works was decommissioned following the completion of Kangawa Works
in 2009. However, the technologies that have supported the development of our company
live on at Kangawa Works.

44
November 2017

SANYO DENKI TECHNICAL REPORT
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Technologies Offering Value in New Fields

Major Operating Officer Toshihiko Baba

Feature: Technologies Offering Value in New Fields

1

3■ Cooling Systems Division

Cooling Systems Division
Technologies Offering Value in New Fields

Satoshi Fujimaki ......................................... 3

High Performance Blower San Ace B97 9BMC Type
G Proof Fans San Ace 120GP and San Ace 172GP

Munenori Takakuwa and Others ..... 7

Naoya Inada and Others .................... 12■ Power Systems Division

Power Source-Related Technologies
Offering Value in New Fields Shinji Kondo and Others ............................................................... 17
Developing Web Applications
for Power Management Products

Yuki Hara and Others ......................................................... 21

Development of the Small-Capacity UPS
SANUPS A11K-Li and SANUPS N11B-Li Series
Development of the SANUPS P73L
PV Inverter with a Peak Cut Function

Yuhei Shoyama and Others ..................... 25

Tetsuya Fujimaki and Others ........................................ 34■ Servo Systems Division

Servo Systems Products Offering Value in New Fields

Yasushi Misawa and Others ..... 43

Development of the SANMOTION R 3E Model
EtherCAT Servo Amplifier Hiroyuki Kosuge and Others ............................................................... 49
Development of the SANMOTION R 3E Model Safety
Servo Amplifier Hideki Netsu and Others .......................................................................................... 54

Technologies Offering Valuein New Fields

Toshihiko Baba
Major Operating Ofﬁcer

How wonderful it would be if customers around the world appreciatedus and thought “I’m so happy I chose a SANYO DENKI product”!
With this feedback from our customers as our driving force, SANYODENKI is pushing forward globalization of our businesses.
In our 8th Mid-term Management Plan, we have established the goalof “making SANYO DENKI a top brand in the world.” Under that goal,
we are engaged in an initiative “specialists in change” as well as theabovementioned “globalization.”Why “Specialists in Change”?
The environment that surrounds us is constantly changing. If we takeaction after a change has already occurred, that action will be too late
and we will be swept away by the wave of change. We must seize theinitiative by always anticipating and preparing for changes so we can act
when necessary. In fact, it is important that we become the ones thatmake change rather than waiting for it.
Here, let’s think about the feature theme of this report “Technologies
Offering Value in New Fields.”“New fields” refers to fields expected to grow in the future. We need to
be alert to the changes taking place in the world in order to identify thefields expected to grow. Moreover, by sensing the seeds of these changes,
then nurturing those seeds ourselves, we become the ones that make thechange happen.
Next I will introduce examples of the “new fields” SANYO DENKI isinvolved in by each business category.
In the Cooling Systems Division, we are expanding the sale of our
products to the “multi-purpose non-cooling market.”Previously, most of the fans designed and manufactured by our
Cooling Systems Division were embedded in our customers’ devices andused for the purpose of cooling heat-generating areas. A typical example
is a fan that cools the CPU inside a computer.
In addition to fans designed for cooling purposes, we are now targeting
markets where fans are used for ventilation purposes. A recent example
is the adoption of SANYO DENKI fans for household ventilation in
Europe. This is the perfect example of penetrating a new field.

1

SANYO DENKI Technical Report No.44 November 2017

For the Power Systems Division, SANYO DENKI was one of the firstcompanies to enter the PV inverter field supporting photovoltaic energy,
which is gathering a lot of attention as a renewable energy source. Not
stopping at this, we also expanded to PV inverter fields for wind power
generation and hydroelectric power generation applications.
The Servo Systems Division has been providing the servo motors used
in industrial robots since the 1980s. In recent years, robots have begun
being used in fields closely related to human beings. A typical example
is robots for nursing care applications. Our servo system products weresome of the earliest to be adopted in robots for nursing care.
Our three brands San Ace, SANUPS, and SANMOTION all produce
energy converting devices. Reducing the loss of each product, inother words, improving conversion efficiency, is a major theme we areconstantly pursuing. We believe that the feature theme of this report“Technologies Offering Value in New Fields” should be discussed fromthe perspective of improving conversion efficiency.
Moreover, in addition to technologies that improve the conversion
efficiency of equipment, key sub-themes of “Technologies Offering
Value in New Fields” are “people-friendly equipment” and “connected
equipment.”
A straightforward example of “people-friendly equipment” is theaforementioned robot used in nursing care. We will continue providing
the world with more equipment which users truly find easy to use.
As for “connected equipment,” IoT technology is a good example, andis attracting a large amount of attention from people the world over.
SANYO DENKI wishes to equip its products with this IoT technology
so we can constantly offer our customers and society at large the joy(value) of such products.
This completes my brief introduction to “Technologies Offering Valuein New Fields.”
SANYO DENKI is pushing forward with initiatives to work withour customers across the globe in solving their issues and helping theirproducts become number one in the industry. Through this initiative,
we will continue corporate activities that bring joy to our customers
worldwide.

SANYO DENKI Technical Report No.44 November 20172

Feature: Technologies Offering Value in New Fields

Cooling Systems Division
Technologies Offering Valuein New Fields
Satoshi Fujimaki

1. Introduction

For the ø136 mm model, equivalent performance had
been achieved in airflow vs. static pressure characteristics

New products sold in various fields worldwide always

and power consumption for both directions. However,come equipped with many new functions with their

there was a sound pressure level (SPL) difference of more

performance greatly improved. With that in mind, to offer

than 10 dB(A), which needed to be improved. In order toour customers the fans they need now and in the future,

improve the SPL of the newly-developed ø92 mm model, we

SANYO DENKI proactively listens to our customers’

incorporated new technology in the blade shape. A concrete

requests and problems, while providing technical support,

explanation is provided below.

so that we may develop new technologies and products
which fulfill customers’ needs.

Considering its particular application, the aim of theReversible Flow Fan is to blow air in both forward andWhile such technologies and products enjoy demand

reverse directions, therefore there is a need for the airflow

from typical applications such as ICT equipment, industrial

vs. static pressure characteristics and SPL to be equal inequipment, industrial inverters, and measuring devices, theyboth airflow directions.

can also offer value to new applications and new fields.

The shape and mounting angle of the blades significantly

This article will introduce our achievement in terms ofchange the airflow vs. static pressure characteristics astechnologies offering value in new fields, using the following

well as impact SPL and power consumption. SPL tends torecent products as examples: the Reversible Flow Fan

increase particularly in the reverse airflow direction due tothat can blow air in both directions, the Airflow Tester tothe spokes supporting the motor on the air suction side.

measure the operating airflow and system impedance ofTo minimize SPL, the surface area of the blades was

equipment, the PWM Controller for controlling the speed

increased and the shape designed to optimize pressureof PWM control function fans, and the G Proof Fan that can

distribution on the blade’s surface so that the necessary

withstand high levels of G-force.

airflow could be obtained without increasing fan speed.

2. Reversible Flow Fan

surface of a blade in the Reversible Flow Fan obtained by

Figure 1 shows an example of pressure distribution on the

The Reversible Flow Fan is designed mainly for use inperforming fluid analysis. Figure 2 is an external view of theblade.

non-cooling applications. Its unique characteristic is thatit can blow air in two switchable directions with equivalent
airflow and power consumption performance in both
directions. As this product mainly targets the household
ventilation market, the new models have circular shape with
136 mm and 92 mm diameters unlike normal square-shaped
axial fans in order to match the common size of household
ventilation ducts.
Technical Report No. 40 and No. 42 already introduced
the first generation ø136 mm sized Reversible Flow Fan,
therefore this article will focus on the technology newly
adopted in the next-generation ø92 mm model.

3

SANYO DENKI Technical Report No.44 November 2017

Fig. 1: Example of pressure distribution
on the blade surface using fluid analysis

Cooling Systems Division Technologies Offering Value in New Fields

the San Ace Airf low Tester to easily measure system
impedance and operating airflow and offer value in new
fields. The Airflow Tester is a portable measuring device
that uses the highly accurate double chamber method.
Figure 3 is an external view of the Airflow Tester.

Fig. 2: Blades
By adopting a SANYO DENKI-original shape for theblades, we were able to achieve surface distribution with

Fig. 3: Airflow Tester

only moderate pressure change and reduce flow separation.
As a result, the airflow vs. static pressure characteristics isequal for the forward and reverse directions and there isminimal difference in SPL.

At L600 mm × H250 mm × W250 mm and 6 kg, theAirflow Tester can be carried and used by a single person.

This technology has reduced the SPL difference between

To make it lighter, the main body of the Airflow Tester

forward and reverse directions from 11 dB(A) of the ø136

is made of high-performance plastics for high strength.

model to 4 dB(A) of the ø92 model.

Moreover, th roug h strength a nd f lu id a na lyses, weHence, this technology has proved effective for the
Reversible Flow Fan.

were able to design a lightweight shape that maintains
strength. Finally, by integrating the power source, control
components, sensors and other necessary components to

3. Airflow Tester

the main body of the tester, we have achieved a compact
product.

One important element in thermal design is selecting

Our measurement method is adapted from the highly-

the optimal fan for a device. It requires, however, to know

accurate double chamber method as per JIS-B-8330. Due tothe system impedance and operating airflow of the device.

the nature of the highly accurate double chamber method,

Measurement of these allow you to easily identify the fan’s

there is a need to change the size of the nozzle depending

operating point, and select a fan with consideration to theon the airflow being measured. For this reason, multiple

equipment’s cooling margin, fan SPL, power consumption,

nozzles are necessary. However, rather than fixing theseetc.

nozzles directly to the Airflow Tester’s main body, we haveA measuring instrument known as a “double chamber
measuring device” can accurately measure the system

made them interchangeable to keep the tester’s size to aminimum.

impedance of a device. However, they are extremely

Because the Airflow Tester is small, light, and portable,

expensive, large, and require installation, making themmeasurements can be taken easily without moving fromdifficult to relocate once installed.

the location where the equipment is installed. We have also

Due to this, the majority of users opt to use anemometersand simulations rather than the double chamber measuring
device for the thermal design process and select fansa c c ord i n g ly. However, b e c au s e a nemo met er s a nd

prepared a special-purpose duct which is mounted to theexhaust port to make measurements more convenient.
Figure 4 shows an example of how the Airflow Tester isconnected to equipment.

simulations have poor accuracy compared to double
chamber measuring devices, thermal design and verification
required a great deal of time and effort.
To help solve these problems, SANYO DENKI developed

SANYO DENKI Technical Report No.44 November 20174

Fig. 5: Box typeFig. 4: Example of how an Airflow Tester
is connected to equipment
In this way, the Airflow Tester developed using newtechnology is having a significant impact not only in terms ofequipment thermal design, but also in regard to fan selection
in new fields such as ventilation.
For details on this product, please read SANYO DENKI
Technical Report No. 42 (2016)“Development of the S a n Ace Airf low Te ster - A
Measuring Device for System Impedance and Operating

Fig. 6: PCB type

Airflow of Equipment.”

4. PWM Controller

For use in a variety of applications, the box type comeswith functions to control the PWM signal through four

Many fans in the market use PWM control function totypes of inputs: voltage, variable resistor, thermistor, and thecontrol a fan’s airflow and rotational speed. This type of fan

adjustment knob on the box. The four control functions arecontrols rotational speed using a PWM signal.

installed in the controller in advance, therefore by switching

To do this, one must prepare a special-purpose control
circuit but this requires specialist knowledge.
For this reason, SANYO DENKI developed and released
the San Ace PWM Controller in 2016 which can be usedthe control functions and input circuits with the selector
switch enable it to output a PWM signal linked to eachindividual input. Below listed are the four types of control
functions.

together with the PWM controller-inclusive fan as a set.
This product is a standard controller that enables you to1)Voltage control:

easily utilize PWM control function fans without special

This function converts the voltage signal (0 to 5 V) fromknowledge.

the customer to PWM output duty signal to control fan
speed.

This product can share a DC power source with the PWM
control function fans it is connected to. For this reason, we2) Variable resistor control:

designed new control circuits and achieved a wide-operatingThis function controls PWM output duty signal with

voltage range from 7 to 60 VDC, making it compatible withexternally-connected variable resistor.

all the SANYO DENKI fan’s standard rated voltages 12 V,
24 V and 48 V.
T his product is available in two types to suit ourcustomers’ specific application. These are the “box type”,
shown in Figure 5, and the “PCB type”, shown in Figure 6.

3)

Thermistor control:
The PWM duty signal is automatically controlled
by preset temperature (30 to 50˚C) and the detected
temperature with an external thermistor.

4) Adjustment knob control
The PWM output duty signal is controlled by the
adjustment knob on the box.

5

SANYO DENKI Technical Report No.44 November 2017

Cooling Systems Division Technologies Offering Value in New Fields

In regard to the PCB type, three models have been
produced featuring one of the functions mentioned in 1)

For details, please read the article on this product in thisTechnical Report.

through 3) above.
The right San Ace PWM Controller to suit the particularapplication can be used, making it a user-friendly product.

6. Conclusion

SANYO DENKI is confident that this is an extremely

T h is a r ticle has i ntroduc ed i n itiatives related toeffective solution for customers in a variety of fields thattechnologies offering value in new fields using the products

cannot easily design and fabricate controllers.

developed by SANYO DENKI as examples.

5. G Proof Fan

accurately ascertain our customers’ issues and requests,

We firmly believe we must continue to swiftly andand constantly pursue fan technologies required by our

Inside CT scanners for medical use, the part whichcustomers. Then, leveraging these technologies, we will

irradiates X-rays into the human body rotates at high speed.

engage in the development of products offering value in new

For this reason, the fan used to cool this portion is subjected

fields so that we may, together with our customers, provide

to high levels of G-force.

products that make dreams come true.

CT scanners for medical use are expected to have evenhigher performance in the future, therefore fans that canReferences

operate in environments with even higher G-force will be(1) Toshiya Nishizawa and 3 others:“ø136 mm × 28 mm Thick Reversible Flow Fan San Ace 136RF 9RF

needed.
In order to meet such requirements of the medical industry,
SANYO DENKI has developed and commercialized San
Ace 120GP and San Ace 172GP 9GP type G Proof Fans.
Figure 7 is an external view of the G Proof Fan.

Type”
SANYO DENKI Technical Report No. 40 (2015)(2) Katsumichi Ishihara and 4 others:“Development of the San Ace Airflow Tester– A Measuring Device for System Impedance and Operating Airflow
of Equipment”
SANYO DENKI Technical Report No. 42 (2016)

Satoshi Fujimaki
Joined SANYO DENKI in 1982.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.
San Ace 120GP

San Ace 172GP

Fig. 7: G Proof Fan
By considering actual operating environment to extract
problems when using a fan in environments with G-force
and performing strength analysis using simulations, we havesuccessfully produced a fan able to withstand G-force of up
to 75G.
Each structures of this fan have been strengthened towithstand the target level of G-force.
An aluminum frame has been adopted. In order toimprove the strength of rotating bodies (rotor, blade
assembly, etc.), we have achieved a G-force tolerance of 75G
by adopting a new structural design whereby each component
is fixed, as well as adopted new material and shape.

SANYO DENKI Technical Report No.44 November 2017

6

New Products Introduction

High Performance Blower
San Ace B97 9BMC Type
Munenori Takakuwa

Toshiya Nishizawa

Koji Ono

Hiromitsu Kuribayashi

Akira Nakayama

1. Introduction
Thanks to its compact design and high static pressure, theThe features of the new model are as follows:(1) High static pressure

97 × 33 mm blower is used for air supply in printers and A/C(2) High airflow

units, as well as for cooling in servers and power sources. Its(3) PWM control function

versatility allows it to be used in a wide range of markets andapplications, including office equipment, industrial devices,and household appliances.
SANYO DENKI has developed and released the 97

3. Product Overview
3.1 Dimensions

× 33 mm blower San Ace B97 9BMB type (hereinafter

Figure 2 shows the dimensions of the new model.

“current model”). However, as its applications have become

The new model has the same mounting dimensions as themore compact while improving performance, blowers are

current model, therefore compatibility is maintained.

also expected to increase performance.
In response, SANYO DENKI newly developed andreleased the 97 × 33 mm blower San Ace B97 9BMC type
(hereinafter “new model”) which achieves the highest

3.2 Specifications
3.2.1 General specifications
Table 1 shows the general specifications.

cooling performance in the industry*.
This paper provides a detailed introduction of this new
product.

3.2.2 Airflow vs. static pressure
characteristics
F i g u r e 3 s h ow s t h e a i r f l ow v s . s t a t i c p r e s s u r e

2. Product Features
Figure 1 shows an external view of the new model.

characteristics for the new model.

3.2.3 PWM control function
Figure 4 shows an example of the airflow vs. staticpressure characteristics for different values of PWM duty
cycle. The new model has a PWM control function thatenables external control of fan speed.
By controlling the fan’s speed to suit the device’s heatgeneration state rather than operating it at full speed
constantly, both the overall device power consumption andnoise can be reduced. Therefore, the demand for fans with a
PWM speed control function has increased significantly inrecent years.

3.3 Expected life
Fig. 1: 97 × 33 mm
San Ace B97 9BMC type

7

SANYO DENKI Technical Report No.44 November 2017

The new model has a expected life of 40,000 hours at 60˚C(survival rate of 90%, run continuously at rated voltage in afree air state and at normal humidity).

High Performance Blower San Ace B97 9BMC Type

(1
8.
6)

(1.5)

(21)

1
.2±
R51

(52)
(8)

)

4-ø4.5±0.3
Mounting hole

AIR FLOW

ø56±1

26±0.332±0.3(5)(1039±0.331.5±0.3(10)39±0.332±0.3(58)

Lead wire
Rated voltage 12 V fan
AWG 20
UL 1430
Rated voltage 24 V fan
AWG 24
UL 1430300±3097.1±1

(50)

(1.5)

(1
8.
6)

1
.6±

(1.5)

39±0.345±0.3
95±1

R5 9

33±1
(2.4)

Airflow direction

Rotating direction

Fig. 2: Dimensions of the new model (unit: mm)Table 1: General characteristics of the San Ace B97 9BMC type
Rated
voltage[V]

Model No.

PWM
Operating
Rated
duty
voltagecurrent
Note 1,2
range cycle
[A]
[%]
[V]

Rated
Input
[W]

Rated
Max. airflow
speed[min-1] [m 3/min] [CFM][Pa]

Max. staticpressure

Operating
SPL
Expected life
temperature[dB (A)][h][˚C][inchH2O]

9BMC12P2G001

1210.8 to
13.2

100

6.2

74.4

8,200

1.85

65.3

1,950

7.83

69

20

0.38

4.56

2,800

0.58

20.4

121.0

0.48

44

9BMC24P2G001

24

21.6 to
26.4

100

3.1

74.4

8,200

1.85

65.3

1,950

7.83

69

20

0.19

4.56

2,800

0.58

20.4

121.0

0.48

44

（inch H2O）

（Pa）

8

2000

-20 to +70

40,000 at
60˚C(70,000 at
40˚C)

Note 1. Input PWM frequency: 25 kHz
Note 2. Speed is 0 min -1 at 0% PWM duty cycle（inch H2O）

（Pa）

8

2000

PMW duty 100%

7

7
1500

6
Static pressure

Static pressure

6
5
4

1000

3
2

Rated voltage

PMW duty 100%
1500

5
4

1000

60%

3
500

2

500
20%

1
0

1

0

10

20

30

2.0 （m3/min）

1.5

1.0

0.5

0

40

50

60

70 （CFM）

Airflow

Fig. 3: Airflow vs. static pressure characteristicsof new model

0

図版の文字

0.5
123

0
0

10 英語版用
20
30
Condens
英語版用

2.0 （m3/min）

1.5

1.0
40

50

60

70 （CFM）

Airflow

Times Ten

Fig. 4: Example of the airflow
vs. static pressure characteristics
for different values of PWM duty cycle.

SANYO DENKI Technical Report No.44 November 20178

4. Key Points of Development
The new model achieves high static pressure and highairflow by adopting a large 3-phase motor and a newlydesigned impeller, and higher rotational speed compared tothe current model.
Current model

The key points of development are explained as follows.

New model

Fig. 6: Impeller shape of current modeland new model

4.1 Motor design
When rotational speed is increased, the motor generates
more heat. In other words, in order to increase rotational
speed, the motor must have high efficiency to minimize

5. Comparison with the Current Modelits heat generation. The current model adopts a 4-slot,

The newly designed impeller and large 3-phase motor

single-phase motor; however, the new model adopts aof the new model result in higher rotational speed andhigher-efficiency, large 6-slot, 3-phase motor to keep heatsignificantly improved static pressure and airflow over thegeneration to a minimum and enable higher rotational

current model.

speed.

The following is a comparison of the characteristics of the

Figure 5 shows the motor portion of the current model andnew and current models.

new model.

5.1 Comparison of airflow
vs. static pressure characteristics
Figure 7 gives a comparison of the airflow vs. staticpressure characteristics for the new model 9BMC12P2G001
and 9BMB12P2K01, a current model of the same size.
Both the static pressure and airflow have been significantly
increased, with maximum static pressure 1.5 times greaterand maximum airflow 1.15 times greater.
Current model

New model

Fig. 5: Motor of the current model and new model

1800
1600

4.2 Impeller design
A high static pressure can be obtained by increasing
also results in increased sound pressure level (SPL). We
engineered the shape of the bottom of the impeller tofacilitate smoother airflow. As a result, we achieved higher
rotational speed while suppressing the increase in SPL asmuch as possible.
Moreover, to achieve high-speed rotation, we had to
improve the rigidity of the impeller to withstand centrifugal
force at high rotation. By creatively designing the shapeof the guide at the top of the impeller, we have increased
rigidity and made impeller diameter even wider. We useda 3D printer during design verification and repeatedly

New model(9BMC12P2G001)

1.5 times

1400
Static pressure ［Pa］

blower rotational speed. However, higher rotational speed

PMW duty 100%, 12 VDC

2000

1200
1000
800
600

Current model(9BMB12P2K01)

400
200
0

1.15
times

0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Airflow ［m3/min］

measured the model to find the optimal blade shape andachieve high static pressure and high airflow.
Figure 6 shows the shape of the impeller for both the newand current models.

9

SANYO DENKI Technical Report No.44 November 2017

Fig. 7: Airflow vs. static pressure characteristics

High Performance Blower San Ace B97 9BMC Type

5.2 Comparison at assumed system
impedance

2.0
1.8

Figure 8 shows a comparison of the “airflow vs. static
9BMC12P2G001 and current model 9BMB12P2K01 as
well as the assumed system impedance curve. System
impedance indicates the aerodynamic load specific toa piece of equipment. Therefore, the point where thesystem impedance curve and airflow vs. static pressure
characteristic curve intersect indicates the operating point

1.6
Operating flow ［m3/min］

pressure and SPL characteristics” of the new model

1.2

1.18

0.8
0.6
0.4

achieves higher rotational speed with high static pressure

0.2

69 dB(A) in a free air state which is 3 dB(A) higher than the

1.45

%

1.0

of the blower used in the target equipment. The new modeland high airflow. As such, the new model has an SPL of

+23

1.4

0.0
Current model(9BMB12P2K01)
SPL at operating point:
66 [dB(A)]current model’s SPL of 66 dB(A).
However, the difference in SPL becomes even smaller
depending on the system impedance of the equipment on

New model(9BMC12P2G001)
SPL at operating point:
66 [dB(A)]Fig. 9: Comparison of operating flowat the operating pointwith the assumed system impedance

which the blower is used. Figure 9 shows the airflow at theoperating point of the assumed system impedance shown in

図版の文字

Figure. 8.

123

At the operati ng poi nt w ith th is assu med system
impedance, the SPL of the current model and the new model
was the same at 66 dB(A); however, the operating airflow of

英語版用

6. Conclusion

Condens

英語版用

Times Tenthe current model is 1.18 m3/min compared to 1.45 m3/min ofThis article has presented some of the features andthe new model. The new model achieves 23% higher airflow

performance of the high performance 97 × 33 mm blower

than the current model while maintaining the same SPL.

San Ace B97 9BMC type developed by SANYO DENKI.
The new model has increased rotational speed and

SPL at operating pointof the new model: 66 [dB(A)]SPL of the current model(9BMB12P2K01)

SPL at operating
point of thecurrent model:
66 [dB(A)]2400
New model(9BMC12P2G001)

Static pressure ［Pa］

2000

60

50

motor and a newly-designed impeller.
The 97 × 33 mm blower has been used in a variety of
applications thanks to its compact design and high staticpressure performance, making it ideal for cooling and air
supply applications in small spaces. By achieving evenhigher static pressure and airflow on the new model,such as high performance and space efficiency. We also
believe this product can offer value for equipment in new

Operating pointof the new model

1200

fields.
* As of May 25, 2017. Compared with blowers of equivalent size.
Investigated by SANYO DENKI.

800 Current model

Operatingpoint of thecurrent
model(9BMB12P2K01)

400 Assumed system
impedance

0.0

70

airflow than the current model by adopting a large 3-phase

SANYO DENKI offers new value for existing equipment,

1600

0

achieves significantly higher static pressure and higher

80
SPL [dB(A)]PMW duty 100%, 12 VDC
SPL of the new model(9BMC12P2G001)

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

Airflow ［m3/min］

Fig. 8: Airflow vs. static pressure vs.
SPL characteristics example
図版の文字

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Condens

SANYO DENKI Technical Report No.44 November 201710

High Performance Blower San Ace B97 9BMC Type

Munenori Takakuwa
Joined SANYO DENKI in 1998.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

Toshiya Nishizawa
Joined SANYO DENKI in 1999.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

Akira Nakayama
Joined SANYO DENKI in 2005.
SANYO DENKI PHILIPPINES, INC., Design Dept.
Works on the development and design of coolingfans.

Koji Ono
Joined SANYO DENKI in 2015.
Cooling Systems Div., Design Dept.
Works on the development and design of cooling
fans.

Hiromitsu Kuribayashi
Joined SANYO DENKI in 1996.
Cooling Systems Div., Design Dept.
Works on the development and design of cooling
fans.

11

SANYO DENKI Technical Report No.44 November 2017

New Products Introduction

G Proof Fans
San Ace 120GP and San Ace 172GP
Naoya Inada

Jiro Watanabe

Atsushi Yanagisawa

Masato Kakeyama

Masaki Kodama

Tetsuya Yamazaki

1. Introduction
In recent years, there has been a growing demand for fansable to be used in environments subjected to centrifugal
acceleration, commonly known as G-force. One example isthe fan used for cooling the interior of medical CT scanners.
Medical CT scanners have a high-speed rotating gantry
that scans the human body. For this reason, the fan thatcools the gantry is subjected to high levels of G-force. It isbelieved that medical CT scanners will offer even higher
performance and higher reliability, leading to greater
demand for fans that can be used in environments withhigher levels of G-force.
To meet such demands in the medical industry market,
SANYO DENKI developed and produced the San Ace

Fig. 1: 120 × 120 × 38 mm G Proof Fan
San Ace 120GP 9GP type

12 0 GP and San Ace 172GP 9GP type G Proof Fans(hereinafter, “new product”).
This article will introduce the features and performanceof the new model.

2. Product Features
The features of the new product are:
(1) Ability to withstand G-forces of 75 G
(2) Low power consumption(3) PWM speed control function
Figures 1 and 2 show external views of the new product.

Fig. 2: ø172 × 150 × 51 mm G Proof Fan
San Ace 172GP 9GP type

3. Outline of the New Product3.1 Dimensions
Figures 3 and 4 show the dimensions of the new products.
T he fan’s external dimensions and mounting holedimensions are compatible with our existing product.

SANYO DENKI Technical Report No.44 November 201712

8-ø4.5±0.3
Mounting hole8-ø4.5±0.3
Mounting hole

+30
300 0

162±0.5ø172±0.8120±0.8
104.8±0.3

10
30 0

+30
0

Lead wire
AWG 18
UL 1430（10）

Lead wire
AWG 24 6.5±0.3
UL 1430 3.5±0.3

104.8±0.3
120±0.8

Rotating direction

6.5±0.3
3.5±0.3

55.5° 55.57.5±0.4°

7.5±0.438±0.5150±0.851±0.8Airflow direction

Rotating direction

Airflow direction

Fig. 3: Dimensions of the 120 × 120 × 38 mm
San Ace 120GP (unit: mm)

3.2 Specifications
3.2.1 General specifications

Fig. 4: Dimensions of the ø172 × 150 × 51 mm
San Ace 172GP (unit: mm)

図版の文字

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123

123

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Tables 1 and 2 show the general specifications for the new product.
Condens

英語版用

英語版用

英語版用

Condens

Times Ten
Table 1: General specifications of the
120 × 120 × 38 mm San Ace 120GP

Model No.

9GP1224P1G001

9GP1248P1G001

Rated
voltage[V]
24

Operating PWM
Rated Rated
voltagedutycurrent input
range
cycle
[A]
[W]
[V]
[%]
15 to 3048

36 to 60

Rated
speed
[min-1]Times Ten

Max. staticpressure[m3/min] [CFM][Pa]Operating
Level of
Expected
SPL temperature
G-forcelife[dB (A)]
range
tolerance[h][inchH2O][˚C][G]Max. airflow

100

1.60

38.40

6,550

7.00

247.1

370

1.48

62

20

0.12

2.88

2,000

2.13

75.2

34.4

0.13

36

100

0.80

38.40

6,550

7.00

247.1

370

1.48

62

20

0.08

3.84

2,000

2.13

75.2

34.4

0.13

36

Note: Speed is 0 min at 0% PWM duty cycle-20 to +70

40,000at 60˚C

75* Input PWM frequency: 25 kHz-1Table 2: General specifications of the ø172 × 150 × 51 mm San Ace 172GP
Model No.

9GP5724P5H001

9GP5748P5G001

Rated Operating
voltage voltage
[V]
[V]
24

48

16 to 3036 to 72

Rated
speed
[min-1][m3/min] [CFM][Pa]Operating
Level of
Expected
SPL temperature
G-forcelife[dB(A) ]range
tolerance[h][inchH2O]
[˚C]
[G]

100

5.0

120

8,000

12.3

434

1,000

4.02

77

20

0.5

12.0

3,000

4.6

162

175

0.70

51

100

5.0

240

10,500

16.1

568

1,600

6.43

83

20

0.41

19.7

3,700

5.6

198

250

1.01

57

Note: Speed is 0 min -1 at 0% PWM duty cycle

13

Max. staticpressure

PWM
Rated Rated
duty
current input
cycle
[A]
[W]
[%]

SANYO DENKI Technical Report No.44 November 2017

Max. airflow-20 to +70

40,000at 60˚C

75* Input PWM frequency: 25 kHz

G Proof Fans San Ace 120GP and San Ace 172GP

3.2.2 Highly resistant to G-forces

3.2.4 PWM control function

The new product is able to withstand G-forces of up to

The new product is equipped with the PWM control

75 G (at normal temperature, normal humidity, continuousfunction that enables external control of fan speed,

operation).

contributing to lower sound pressure level (SPL) and lower
power consumption.

3.2.3 Airflow vs. static pressure
characteristics

3.3 Expected life

Figures 5 and 6 show the airflow vs. static pressure
characteristics for the new product.

The new product has an expected life of 40,000 hours at
60˚C (survival rate of 90%, when run continuously at rated
voltage in free air and at normal humidity).

24/48 VDC
PWM duty 100%（inch H2O）（Pa）

450

STATIC PRESSURE

1.5

9GP1224P1G001
9GP1248P1G001

350

In order to develop a product never before seen on themarket, we needed to consider how it is actually used. As

300
1.0

such, we identified the issues that occur when a fan is used

250

in an environment with high G-force. We also conducted

200
0.5

0

4. Key Points of Development

400

strength analysis using simulation and investigated a new

150

structure. By adopting this new structure based on the100

analysis results, we successfully produced a fan able to50

withstand G-forces of up to 75 G.

0

1
0

2
50

3

4

100

5

6

8 （m3/min）
（CFM）

7

150
200
AIRFLOW

250

Fig. 5: Airflow vs. static pressure characteristicsof the 120 × 120 × 38 mm San Ace 120GP

The key points of development are explained below.

4.1 CT scanner application example
Medical CT scanners create cross-sectional images of the
body using an X-ray source and detectors that rotate aroundthe patient. Multiple fans are used to cool the detectors.
Currently, there is a demand to shorten the scan time of（inch H2O） （Pa）

7.0

1800

24/48 VDC
PWM duty 100%CT scanners, therefore efforts are being made to increase

9GP5748P5G001

levels of G-force that accompany high-speed rotation is

STATIC PRESSURE

6.0 1500

required.
9GP5724P5H001

5.0 1200
4.0

1.0
0

Figure 7 illustrates how the new product can be used in a

英語版用

medical CT scanner.

Condens

900

英語版用

Times Ten

3.0
2.0

rotational speed. As such, a fan able to withstand the high

600
300

4

0
0

100

200

8

12

300

400

20 （m3/min）

16
500

600

700 （CFM）

AIRFLOW

Fig. 6: Example of the ø172 × 150 × 51 mm
San Ace 172GP airflow
vs. static pressure characteristics
Fig. 7: Example of a fan being used
in a medical CT scanner

英語版用Condens

英語版用

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SANYO DENKI Technical Report No.44 November 201714

4.2 Ability to withstand G-forces

4.4 Frame design

The ideal product is one that could be used in multiple

T he frame must have high rigidity, so we used an

mounting directions to suit various operating environments.

aluminum frame. Moreover, using simulation, we identified

For this reason, we developed a fan that can operate

where strength needed to be improved and increased

normally even when subjected to G-forces of 75 G from thestrength without sacrificing fan performance, thus ensuring

X, Y or Z axial directions.

the fan’s ability to withstand stress when under a load.

Figure 8 shows the directions of G-force able to be

4.5. Structural design

withstood by the fan.

For structural design, first we identified the problems that
TI

EC

IR
SD

arise in environments subjected to G-force, then conductedON

simulation analysis to pinpoint where strength needed to be

XI

Z-A

improved. Through this, we improved rigidity by selectively
increasing strength.

Y-AXIS DIRECTION

Below is an overview of the points that have beensignificantly improved compared with the existing structure.
(1) Improved rotor bushing rigidity
A rotor bushing is used to join the rotor cover and shaft.
To increase rigidity and increase strength, we reviewed the
X-

AX

IS

rotor bushing material and fixing method.
DI

RE

CT

IO

(2) Bearing retention

N

Fig. 8: Withstandable G-force directions

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123

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Fans use bearings to secure rotating parts suchas the rotor

and impeller.

Condens

英語版用

Times Ten parts
When a fan is subjected to G-force, its rotating

4.3 Impeller design

are constantly subjected to an opposing force. In order to

To develop a fan able to tolerate G-forces as high as 75 G,

withstand this force, we designed a structure that secures

we had to create an impeller structure that could withstand a

the bearings to withstand a greater external force than thehigh load. As such, we employed a structure that integrated

structure of the existing model.

the blades and rotor cover. By increasing joint strength, theimpeller can withstand a high load.
Figure 9 shows an external view of the new product’s
impeller.
Blade (plastic)
Rotor cover(integrated with plastic blades)

Shaft

Rotor bushFig. 9: Impeller of the new product

図版の文字

123

英語版用

Condens

英語版用

Times Ten

15

SANYO DENKI Technical Report No.44 November 2017

G Proof Fans San Ace 120GP and San Ace 172GP

5. Conclusion
This article has presented some of the features andperformance of the 120 × 120 × 38 mm San Ace 120GP and

Naoya Inada
Joined SANYO DENKI in 2007.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

ø172 × 150 × 51 mm San Ace 172GP 9GP type G Proof Fansdeveloped by SANYO DENKI.
Through adopting a new design with higher rigidity, thenew product is capable of withstanding G-forces of up to
75 G and is the industry’s first* product able to withstandJiro Watanabe
Joined SANYO DENKI in 1978.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

G-forces.
We believe this product will not only contribute tocooling of medical devices such as CT scanners, which are
increasing in performance and subjecting fans to G-force,but also contribute to the development of new markets.

Atsushi Yanagisawa
Joined SANYO DENKI in 2006.
Cooling Systems Div., Design Dept.
Works on the development and design of cooling
fans.

SANYO DENKI wishes to continue developing products
for all kinds of environments and markets, as well as

Masato Kakeyama

products that contribute to the creation of new value, so

Joined SANYO DENKI in 2013.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

that we may provide products that make dreams come true
together with our customers.
* Based on our own research as of August 25, 2017, amongequally sized axial DC cooling fans on the market.

Masaki Kodama
Joined SANYO DENKI in 2015.
Cooling Systems Div., Design Dept.
Works on the development and design of coolingfans.

Tetsuya Yamazaki
Joined SANYO DENKI in 1997.
Cooling Systems Div., Design Dept.
Works on the development and design of cooling
fans.

SANYO DENKI Technical Report No.44 November 201716

Feature: Technologies Offering Value in New Fields

Power Source-Related Technologies
Offering Value in New Fields
Shinji Kondo

Masahiro Uchibori

Shinichiro Yamagishi

1. Introduction

Yutaka Katofor servers and ICT devices or for embedding in industrial
devices. In recent years, due to the recent spread of mobile

The Paris Agreement was adopted at COP21 in 2015devices and lessons learned from natural disasters, use as

as a groundbreaking initiative seeking efforts to reduce

backup power for outdoor equipment has emerged as a new

greenhouse gases by all major greenhouse gas-producing

field for small-capacity UPSs, such as cellular base stations,

nations including the U.S. and China, and to establish theirparking meters, outdoor surveillance cameras, traffic lights,

own targets, and conduct mutual reviews on a global level.

and emergency equipment.

Japan established the target of reducing greenhouse gas

UPSs used for these outdoor equipment must have aemissions by the year 2030 by 26% compared to the 2013

wider operating temperature range due to environmental

level. This was verified to be an extremely high target fromrequirements. Moreover, since regular inspections andthe global comparison indicator of cost required for such

replacement cannot be easily carried out for UPSs of thisreduction by individual countries announced afterwards.

use, UPSs for outdoor use must be maintenance-free.

Meanwhile, following the Great East Japan Earthquake,

Furthermore, social infrastructure equipment such as

Japan’s energy self-sufficiency rate fell from 20% to 6%, itstraffic lights and equipment used during disasters such as

dependence on fossil fuels climbed from 62% to 88% andemergency wireless systems are required to have longer

electricity prices rose by around 20% for households andpower failure backup time due to lessons learned fromaround 30% for industrial. The increasing cost of energy

previous natural disasters.

procurement is a major issue impacting the ability of theAlso, because UPSs used outdoor often have only limited

manufacturing industry to maintain its competitiveness. To

installation space available, they must be compact as well as

advance energy conservation while raising the economic

provide prolonged backup. Conventional lead-acid batteries

growth rate, we must engage in fresh initiatives for overall

can provide a relatively short backup time per batteryenergy management using AI, IoT (Internet of Things),

volume and mass, so a large installation space is necessary

and related new services and products as well as developing

to achieve prolonged backup. Moreover, deterioration oftechnological innovations for next-generation power

lead-acid batteries is severe at high and low temperatures,

semiconductors, hydrogen utilization, and storage batteries.

therefore the battery must be replaced after only short

SANYO DENKI must promote product development withperiods of outdoor use.

these new fields in mind.

To solve these issues, we developed the SANUPS N11B-

This article introduces initiatives by the Power Systems

Li series that uses a Li-ion battery (hereinafter “LIB”) with

Division relating to UPS and renewable energy products

superior energy density and service life. This UPS also hasthat can offer value in new fields.

a power conversion unit that generates minimal heat, and a
housing for outdoor use.

17

2. Development of SANUPS N11B-Li:
Power Supply Technology for Fields
Seeking Environmental Durability

the benefits of prolonged backup in smaller installation

Compared to conventional lead-acid batteries, LIB offers
spac e a nd el i m i nated batter y replac ement reduc es
maintenance work. Moreover, by creatively mounting UPS

Until recently, small-capacity UPSs (uninterruptible

components, improving the performance of its coolingpower supply) with an output capacity of 5 kVA or lesssystem, and by adopting LIB with high temperature

were primarily used in indoor equipment such as backup

resistance, the SANUPS N11B-Li series has achieved a wide

SANYO DENKI Technical Report No.44 November 2017

Power Source-Related Technologies Offering Value in New Fields

operating range between -20 and +50˚C. Also, thanks to its

these market needs with the development of the SANUPS

stainless steel IP65 housing, it can be used outdoors even in

P73L PV inverter. Below is an overview of the product andharsh environments.

its features.

As a power backup technology, the SANUPS N11B-

The SANUPS P73L comprises of a 10 kW PV inverter

Li series is anticipated to be used in high-growth sectors

unit, 10 kW charging unit, and I/O box. It is scalable up tosuch as outdoor ICT equipment, traffic lights, and disaster-six 10 kW PV inverters.

prevention equipment.

This product comes in the “grid-connected isolated
charging type” and “grid-connected isolated type,” with
output capacities ranging from 10 to 60 kW. This section will
describe the “grid-connected isolated charging type” as amodel that can be used as a storage battery system.
This model features a peak cut function wherein the
power from the PV panels and storage batteries can besupplied to a general load. Also, it can supply AC power toa specific load even during power outages through isolated
operation. Moreover, during isolated operation, the storage
battery can absorb the power difference between theelectricity supplied to the load and the power generated by
the PV panel while the inverter unit performing tracking
control to maximize the output of PV generation for

Fig. 1: SANUPS N11B-Li

effectively utilizing the PV-generated power.
In addition to these functions, the SANUPS P73L has
achieved parallelization of isolated output, batch PV panel

3. Development of SANUPS P73L:
Power Supply Technology for Fields
which Effectively Utilize Renewable
EnergyPower storage systems are anticipated to contribute

input, and automatic switchover to isolated operation, andcan therefore be proposed as a flexible system to meetcustomer needs.
We expect that the technologies evolved during thedevelopment of SANUPS P73L will contribute to theeffective utilization of renewable energy.

to the realization of a low-carbon society and are a coretechnology of the smart grid. In recent years, competition
has intensified due to market participation by Chinese andKorean manufacturers and venture companies mainly fromthe U.S., leading to a wide-range of storage battery types
and applications. Also, the importance of storage batteries
is growing in terms of both industry and everyday living.
Amidst this, LIB is gathering a lot of attention for achieving
high energy density and long service life, as well as being
small and light compared with conventional lead-acidbatteries.
Moreover, there is an increasing demand from local
governments and private businesses considering installing
backup power sources in preparation of prolonged power
outages during disasters. Of the available systems, power
generation systems combining PV panels and LIB are
attracting interest due to their numerous advantages, suchas the ability to generate renewable energy at point of use,
act as an independent power source during disasters, and

30 kW grid-connectedisolated charging type

30 kW grid-connectedisolated typeFig. 2: SANUPS P73L

minimize power consumption during peak times.
By incorporating an LIB, SANYO DENKI responded to

SANYO DENKI Technical Report No.44 November 201718

4. Development of Generation System
Status Monitoring Service
SANUPS NET:
Information Transmission
Technology for the IoT Field

This service collects information on the PV inverter byusing the SANUPS PV Monitor (hereinafter “PV Monitor”).
The collected information is transmitted to an online cloudserver, then customers can check this information usinga smartphone or other Internet-connected devices, thus
enabling remote monitoring of the PV system’s status.

In recent years, there has been an extremely high

The cloud server uses SMTP, a standard email transmission

level of interest in IoT, or Internet of Things. SANYO

protocol, to request various information from the PV Monitor

DENKI’s power management products adopted network(① in Fig. 3).

communication technology over twenty years ago and

The PV Monitor uses POP3 protocol to verify request

have offered technologies to manage and monitor via aemails from the cloud server (② in Fig. 3) and, if there are any

network. With the expanded utilization of networks, we haverequests, uses SMTP to send the requested data to the cloud

constantly continued to develop new communication methods

server (③ in Fig. 3).

and accumulated network communication technologies that

The cloud server uses POP3 protocol to check if any emails
containing information have been received from the PV

serve as the foundation of IoT.
We have offered power monitoring products for use withbackup products such as UPS, but they primarily assumed use
in in-house LANs. The monitoring of these products aimed at
power supply devices within the same in-house LAN.

Monitor and, if any, saves the information contained (④ inFig. 3).
T h i s c om mu n ic at ion met hod i s secu re a s a l l t he
information transmission within the customer’s network

Meanwhile, PV systems are installed outdoors, therefore

environment is conducted with the PV Monitor as the base

many cases exist in which installation of a dedicated line as

point, meaning there is no direct access to the customer’s

part of an in-house LAN is difficult. However, it has been

network from outside. Moreover, security is assured also indemanded from generation system operators, who introducethat spam is blocked through SMTP authentication when

PV systems for selling electricity, to centrally manage the data

sending emails.

from multiple systems and monitor the operating status of PV

By using this service, customers can safely monitor the
power generation status and operating status of a PV systemsystems from remote locations.
In order to satisfy this kind of demand, SANYO DENKI

via a web browser from a remote location with a computer ordeveloped SANUPS NET as a PV system status monitoring

smartphone as long as there is an Internet connection without

service.

the need to install any special software.

Figure 3 shows an example of system configuration for thisservice.

Installation location of PV generation system

Mail server①SMTP

PV panel④POP3

Internet
Pyranometer

PV inverter

Thermometer
Serial communication (RS-485)

Display, datacollection, download• Power generation status

Cloud server• Daily report graph

②POP3
③SMTP

Router• Operating status

For installation locations where no wired internet access is available,
we offer the Mobile Communications Pack which includes the PV
Monitor, a cellular communication router, and an outdoor housing
in one package.
etc.

Fig. 3: System configuration

19

SANYO DENKI Technical Report No.44 November 2017

Power Source-Related Technologies Offering Value in New Fields

SANYO DENKI wishes to broaden the applicable scope

Shinji Kondo

utilization of products for IoT.

Joined SANYO DENKI in 1985.
Power Systems Div., Design Dept. 2
Works on the development and design of power
supplies and monitoring devices.

5. Conclusion

Masahiro Uchiboriof this service so that it can monitor not only PV systems,
but all kinds of systems and provide a technology for theThis article has introduced the initiatives of the Power
Systems Division which offer value in new fields of the

Joined SANYO DENKI in 2013.
Power Systems Div., Design Dept. 1
Works on the development and design of PV
power systems.

power supply market.
SA N YO DEN K I will continue to sei ze upon newopportunities born from future market changes and exert
every effort in developing technologies that offer new value.

Shinichiro Yamagishi
Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Yutaka Kato
Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept. 2
Works on the development and design of power
supplies and monitoring devices.

SANYO DENKI Technical Report No.44 November 201720

New Products Introduction

Developing Web Applications
for Power Management Products
Yuki Hara

Yutaka Kato

Katsuhiro Yoshizawa

1. Introduction

Kiyoshi Mizuguchi

Hironori Ogihara

graphically displaying the operational status of a UPS on a
web browser (hereinafter Web display tool).

Power management products such as our LAN Interface

Figure 1 is an external view of the LAN Interface Card,

Card have adopted technology for displaying settings via

Fig. 2 shows the Web management tool screen, and Fig. 3

web browser by using “Java applet” technology. Java applets

shows the Web display tool screen.

once had the benefit of being able to provide rich display
features independent of the differences between browser
specifications.
However, due to security reasons, the current trend ismove away from Java applet and other such web application
technologies. In response, as of August 2017, the only webbrowser that still employs Java applets is Internet Explorer.
Moreover, Java applet has been depreciated in version 9of “Java” (hereinafter Java 9), released in September 2017,
there is no longer a recommendation to use Java Applet.
It is aga i nst th is backd rop that SA N YO DEN K I
developed web applications for power management products
using Java Web Start, a replacement technology of Java
applet. This article will provide an overview of this new
solution.

Fig. 1: LAN Interface Card

2. Overview of Power Management
Products
Power management products is the collective termfor optional products used in combination with ouruninterruptible power supplies (hereinafter “UPS”) and PV
inverters.
For example, by combining a UPS with a LAN Interface
C ard, it is possible to mon itor the U P S status a nd
automatically shut down computers during prolonged power
outages. Moreover, a PV inverter combined with SANUPSPV Monitor lets users see and calculate the generated
power volume and monitor the operational status of the PV
inverter.
Configuring and checking the operational history of theseproducts is done through a browser-based Web management
tool. Also, the LAN Interface Card features a function for

21

SANYO DENKI Technical Report No.44 November 2017

Fig. 2: Web management tool

Developing Web Applications for Power Management ProductsJava Applet
Screen is displayed on a web browser
Fig. 3: Web display tool

3. Overview of Java Web Start
As mentioned at the outset, it is becoming difficult to use
applications that operate on web browsers.
Java Web Start deals with this issue by running programs
as application, whereas Java applet runs programs on a
web browser. With this, it is possible to use the same Web
management tool and Web display tool as with Java applet
while maintaining cross-browser usability.
Moreover, as the screen layout has not changed, existingcustomers already familiar with SANYO DENKI’s power
management products and the tools can use Java Web Start
applications with ease.
Figure 4 shows one image depicting the Web management
tool via Java applet and another image via Java Web Start.

Java Web Start
Web management or display tool is opened
as one application
Fig. 4: The display images of Java Applet
and Java Web Start

4. Features of Java Web Start
4.1 How to use the Web management tooland Web display toolB elow i s t he p ro c e du re for d i s pl ay i n g t he Web
management tool of power management products equippedwith Java Web Start. Figure 5 provides a diagram toaccompany the procedure.

SANYO DENKI Technical Report No.44 November 201722

Step 1. Access the power
management product

Step 2. Download
the start-up fileStart-up file
(JNLP file)

Web management toolscreen is displayed
Step 3. Run the start-up fileFig. 5: Steps for displaying the Web management tool using Java Web Start

Step 1: Access the power management productfrom a web browser
Step 2: Download the Web management tool’s start-up
file (JNLP file)

Step 3: Run the start-up ﬁle to launch the Web
management tool

5. Products Targetedby This Development
Table 1 lists the power management products equippedwith Java Web Start as a result of this development.

Table 1: List of power management products
equipped with Java Web Start
Product name

In Step 1, the user downloads a start-up file via web
browser to launch the Web management tool in Java Web
Start. Because no applications are executed in a web

LAN Interface Card
(IPv6-compatible)

browser, it is also possible to launch the Web management
tool on web browsers other than Internet Explorer (Google
Chrome, Firefox, Microsoft Edge, etc.).
Save startup file downloaded in Step 2, then simply
double-click the file to launch the Web management tool.
There is no need to first open a web browser. Thanks tothis feature, power management products can be used withgreater simplicity, as there is no need to run a web browser
to open the Web management tool.
These steps and features are the same for the Web display
tool.

4.2 Continued support of Java applet
Just as before, the Web management tool and Web display
tool can be launched via Java applet even for Java Web Start
equipped products. This feature means customers who must
use Java applet for operational purposes are also supported.

23

SANYO DENKI Technical Report No.44 November 2017

LAN Interface Card(not IPv6 compatible)
LAN Interface Card
(100BASE-TX/10BASET-compatible)
LAN Interface Card
(10BASE-T only)
SANUPS SOFTWARE
Ver.3
SANUPS SOFTWARE
Ver.2
SANUPS T11A/T11B
SANUPS MT15A/
MT15B
SANUPS IT Monitor
SANUPS PV Monitor
Type CSANUPS PV Monitor
E Model
SANUPS PV Monitor
SANUPS Monitor K

Model number
PRLANIF011, PRLANIF012, PRLANIF013,
PRLANIF014, PRLANADP011,
PRLANADP012, PRLANBOX011,
PRLANBOX012
PRLANIF003, PRLANIF004, PRLANIF005,
PRLANIF006, PRLANADP001,
PRLANADP002, PRLANBOX001,
PRLANBOX002
PRLANIF001, PRLANIF002, PRE11A01,
etc.
PRASC04C, PRASD01, PRASE03, etc.
PMS50B00, PMS51B00, etc.
PMS40H00, PMS41H00, etc.
T11A152A001R, T11A202A002R,
T11B152A001R, T11B402A002R, etc.
MT15AW03, MT15BW03, etc.
EV01W02
PVMBC21
PVMB011
PVMB001B
SMON-K-001

Developing Web Applications for Power Management Products

A s m e n t i o n e d a b ove , Jav a a p p l e t i s n o l o n g e r
recommended for use as of Java 9. For this reason, we
extended this development even to the products no longer
available for sale so that our customers currently using our

Yuki Hara
Joined SANYO DENKI in 2013.
Power Systems Div., Design Dept. 2
Works on the development and design of power
supplies and monitoring devices.

power management products can continue using them withconfidence after Java 9’s release.
If existing customers update their power management
product’s program, they will be able to use Java Web Start,
and can continue using their product even after Java 9’s

Yutaka Kato
Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept. 2
Works on the development and design of power
supplies and monitoring devices.

release.

Katsuhiro Yoshizawa

6. Specifications
Table 2 shows the software required to use Java Web Start

Joined SANYO DENKI in 1989.
Power Systems Div., Design Dept. 2
Works on the development and design of power
supplies and monitoring devices.

for displaying the Web management tool and Web display

Kiyoshi Mizuguchi

tool.

Table 2: Required software
SoftwareJava

Web browser

Description
Required to use Java Web Start.
Version 7 or later.
Required to download the start-up file.
Compatible with web browsers such
as Internet Explorer, Google Chrome,
Firefox and Microsoft Edge.
If Internet Explorer, must be Version 8or later.

Joined SANYO DENKI in 1994.
Power Systems Div., Design Dept. 2
Works on the development and design of power
supplies and monitoring devices.

Hironori Ogihara
Joined SANYO DENKI in 2005.
Power Systems Div., Design Dept. 2
Works on the development and design of power
supplies and monitoring devices.

7. Conclusion
This article has provided an overview of SANY DENKI’s
development of web applications for power management
products. As a result of this development, it is now possible
to use Java Web Start on power management products,
allowing our customers to use such products even after the
release of Java 9.
Web technology is evolving daily. SANYO DENKI
will continue moving forward with product development
by quickly identifying changes and applying advanced
technologies in our products.

SANYO DENKI Technical Report No.44 November 201724

New Products Introduction

Development of the Small-Capacity
UPS SANUPS A11K-Li
and SANUPS N11B-Li Series
Yuhei Shoyama

Shinichiro Yamagishi

Yoshitsugu Kashiwagi

Yasuhiko Ogihara

Naoki Shiratori

Hidenori Takizawa

Hirofumi Kimura

Takeo Murai

Kazuya Yanagihara

Shota Ozawa

Hiroyuki Saito

Kazuya Hiraguri

1. Introduction

This article will provide an overview of our new UPS
series SANUPS A11K-Li and SANUPS N11B-Li which are

Conventionally, SANYO DENKI had offered small-embedded with an LIB and correlated interface functions,capacity UPSs for indoor use as backup for servers and ICT

and effectively utilize the large-capacity charging function

equipment or in combination with industrial devices. Inof the current SANUPS A11K UPSs.

recent years, there has been an increased demand for the
backup power for outdoor applications such as base stations,traffic lights, planned power outages, coin-operated parking
lots, and surveillance cameras.

2. Product Overview
The SANUPS A11K-Li is an online UPS while theAssuming outdoor usage will involve exposure to harsh

SANUPS N11B-Li is a standby UPS. Just as the current

environments, requirements include a wide operating

model, the SANUPS A11K-Li can be used as an indoor

temperature range, securing installation space, extended

backup for servers and the like while the SANUPS N11B-Li

backup, and low maintenance.

can be used as backup for equipment installed outdoors.

To date, small-capacity UPSs have used lead batteries;
however, these have a limited operating temperature
range, short runtime towards the end of their life cycle, andrequire replacing. Moreover, to achieve extended backup,
more batteries are needed, which in turn requires moreinstallation space.
By adopting Lithium-ion batteries (hereinafter “LIB”),
UPSs can be used in a wider operating temperature range
compared to conventional lead storage batteries. Other
benefits include extended backup, space-saving, andno need for battery replacement, making the UPS low
maintenance.

25

SANYO DENKI Technical Report No.44 November 2017

2.1 The SANUPS A11K-Li
The SANUPS A11K-Li lineup includes models with
output capacities of 1.5, 3, and 5 kVA.
Figure 1 shows the appearance of the SANUPS A11K-Li
series.

Development of the Small-Capacity UPS SANUPS A11K-Li and SANUPS N11B-Li Series

temperature ranges (-20 to +55˚C for the former and -20 to+55˚C for the latter). This means these products can be usedwith confidence in extremely hot or cold environments.

3.1.2 Low maintenance
T he cu r rent model requ i red batter y replac ement
approximately every five years, but by adopting LIB, the newmodel can be used for up to ten years without the need forbattery replacement. This reduction in maintenance work
1.5 kVA

means battery replacement cost can also be reduced.

3.1.3 Improved maintainability
Tasks such as battery replacement have been made easythrough the modularization of the inverter. Figure 3 shows
an image of the SANUPS N11B-Li equipped with aninverter module and battery modules.
All series models have a maintenance bypass circuit,therefore modules can be replaced without the need tointerrupt power supply from a commercial power source.
3 kVA

3.1.4 Enhanced functionality
An LCD panel is used on the operation panel to improveuser-friendliness and visibility.

5 kVA

Fig. 1: The SANUPS A11K-Li series

2.2 The SANUPS N11B-Li
The SANUPS N11B-Li lineup includes models with
output capacities of 1 kVA and 1.5 kVA.
Figure 2 shows the appearance of the SANUPS N11B-Li
series.

1 kVA

1.5 kVA

Fig. 2: SANUPS N11B-Li series

3. Features
3.1 Common features of the SANUPS A11K-Li
and SANUPS N11B-Li
3.1.1 Wide operating temperature range
Due to the adoption of an LIB, both the SANUPS
A11K-Li and SANUPS N11B-Li have wide operating

SANYO DENKI Technical Report No.44 November 201726

3.3.2 Outdoor installation
The SANUPS N11B-Li uses sealed housing. As such,it can be used as outdoor power backup for base stations,traffic lights, coin-operated parking lots, and so on.
Inverter module

3.3.3 Water resistance and protection
against solid foreign objects
This device adopts a sealed structure, therefore has
excellent water resistance and protection against solid
foreign objects including small insects and animals. Thismeans it can be used outdoors with peace of mind.
The SANUPS N11B-Li achieves a protection rating ofBattery modules

IP65* in protection performance tests.
* Classifi cations defined in “JIS C 0920: Degrees of Protection
Provided by Enclosures (IP Code)”
IP65: No ingress of dust. Devices operate stably even when
directly exposed to water from many directions.

4. Circuit Configuration
Fig. 3: Inverter module and battery modules(the SANUPS N11B-Li, 1 kVA)

Figure 4 shows the circuit diagram for the SANUPS
A11K-Li.
Figure 5 shows the circuit diagram for the SANUPS

3.2. Features of the SANUPS A11K-Li
3.2.1 Space-saving

N11B-Li.
The SANUPS A11K-Li comprises a “power source unit”

Compared to the current model, which uses a lead battery,

consisting of a main circuit, control circuit, communication

the SANUPS A11K-Li can be installed in approximatelyinterface circuit, etc., and a “battery unit” consisting ofhalf the space.

a battery module, battery management unit (hereinafter

Note: If the initial backup time is equivalent

BMU), and other components.
The SANUPS N11B-Li integrates an “inverter module”

3.2.2 Wide input range

consisting of a main circuit and a control circuit, and an “I/O

Just as the current model, the allowable input voltage

portion” consisting of a communication interface circuit,range is wide: -20 to +20% at a load level above 70%, andinput/output circuit, and BMU, etc., and a battery module.

-40 to +20% at a 70% load level or below.
This wide input range makes it possible to reduce the

4.1 LIB monitoring circuit configuration

frequency of operation switchover to battery-feed operation

Equipped with a BMU, this product features a data interface

even when the power source is unstable, as well as minimize

between the UPS and LIB. By monitoring detailed LIB data,

battery wear and deterioration.

and having the UPS and LIB perform mutual protection
operations and fault detections, the LIB can be used safely.

3.2.3 High power factor
As with the current model, the SANUPS A11K-Li has aload power factor of 0.8, therefore can also supply electricity
to high power factor equipment such as servers.

(1) UPS error detection
When an UPS error occurs, notification is sent fromthe UPS to the BMU via CAN communication. Once the
BMU receives notification, it trips the battery breaker.

3.3. Features of the SANUPS N11B-Li
3.3.1 Eco-efficient(2) LIB error detection

With the passive standby topology, the SANUPS N11B-Li

When an LIB error occurs, notification is sent fromsuppresses power consumption and achieves a conversion

the BMU to the UPS via CAN communication. In

ef f ic iency of 95%. T h is reduc es r u n n i ng c osts a nd

response, the UPS stops the charger’s output. Moreover,contributes to energy-saving.

as soon as the BMU detects an LIB error, it trips thebattery breaker.

27

SANYO DENKI Technical Report No.44 November 2017

Development of the Small-Capacity UPS SANUPS A11K-Li and SANUPS N11B-Li Series

that an LIB error has occurred and, as mentioned(3) Monitoring LIB cell voltage and cell temperature

in section (2) above, trips the battery breaker andCell voltage and temperature are measured inseparates the UPS from the LIB.

the battery module and the BMU is notified of themeasurement values through CAN communication.

Users can check the measured values for cell voltage,

If the cell becomes over-charged, over-discharged, orcell temperature, and state of charge on the LCD panel.

reaches an abnormal temperature, the BMU determines

Maintenance bypass circuit
Bypass circuit

AC output
Electronic
switchFuse

FilterFilterAC input

Inverter

Rectifier

Relay

b

DC/DC
converter

a

Relay

Fuse
Invertermodule12 VDCPC I/FCARD I/F

ControlInterface+12 V
power supply

a

+12 V
power supplyb

CHG I/F
BATT I/F
SIGNAL│REMOTE

LANInterface Card
(option)Dry Contact
Interface Card
(option)** Connected to CARD I/F* (Either one)

Expansionbattery connector

Power source unit

EXT. BATTERY

Main battery unit

12 VDCUPS I/F IN

BMU

Relay board

CMU
Expansionbattery
connector

Battery
breakerCurrent
sensor

Fuse

CMU

Battery module

Fig. 4: Circuit diagram for the SANUPS A11K-Li

SANYO DENKI Technical Report No.44 November 201728

Maintenance bypass circuit

Maintenance breaker

Fuse

RectifierInverter

FilterInput breaker(switch)

FilterAC input

Electronic
switchCommercial power
direct transmission
circuitInverter module

ArresterG

ArresteraDC/DCconverter

ServiceoutletOutput breaker AC output

G

Control
FuseaInterface+12 V
power supply

PC I/FCARD I/F
CHG I/F
BATT I/F
SIGNAL│REMOTE

Battery breaker

Current sensor
Relay board
CMU

BMU
CMU

Battery module

Fig. 5: Circuit diagram for the SANUPS N11B-Li

5. Specifications
Table 1 and Table 2 show the standard specifications of the
SANUPS A11K-Li and SANUPS N11B-Li, respectively.

29

SANYO DENKI Technical Report No.44 November 2017

Development of the Small-Capacity UPS SANUPS A11K-Li and SANUPS N11B-Li Series

Table 1: The SANUPS A11K-Li series specifications
Item
Model
Rated output capacity
UPS topology
Cooling system
Type
Inverter system

AC input

AC output

Battery

Unit

Ratings and characteristics
A11KL152 A11KL302 A11KL502
kVA/kW
1.5/1.2
3/2.4
5/4−
Double conversion online−
Forced air cooling−High-frequency PWM

No. of phases/wires
Rated voltage−

Single-phase 2-wire
100, 110, 120
Within ± 20 of rated voltage

Voltage range%

Rated frequency

Hz

Frequency range%

Required capacity

kVA

Power factor−

No. of phases/wires
Rated voltage
Voltage accuracy
Rated frequency

−

V
%
Hz

Frequency accuracy%

Voltage harmonic distortion
Rapid loadchangeDuring power
outage,Transient
recoveryvoltagefluctuation Input voltage
during rapidchangeResponse timePower factor
Overcurrent protection
Inverter
Overload
capability Bypass
Type%

Backup time

Remarks−V

Within -40 to +20 of rated voltage
50 or 60
Within ± 1, 3, 5, or 7of rated frequency
1.5 or less 3.0 or less 5.3 or less0.95 or
0.97 or greater
greaterSingle-phase 2-wire
100, 110, 120
Within ± 2 of rated voltage
50 or 60
Within ± 1, 3, 5, or 7of rated frequency(Default value: ± 3)
3 or less/7 or less

−

%
%
−

MinuteAcoustic noisedB

Ambient temperature
Operatingenvironment Relative humidity
Storage environment

˚C
%
˚C

Same as output voltage
At a 70% load level or greater
At a load level less than 70%
Recovery voltage is -20% of rated voltage or more

(The fluctuation range is the same as the selected
output frequency accuracy)
Max. capacity during battery recovery charging
When input voltage harmonic distortion < 1%
Voltage waveform: Sine wave
At rated output
Same as the input frequency
Frequency accuracy setting can be changed( ± 1, 3, 5, or 7%)
Within ± 0.5% during battery operation (1)Linear load/rectifier load, at rated output
0 ⇔ 100% at transient or output switch

Within ± 5 of rated voltage

At rated output± 10% variation%
Or less

Commercial synchronous online double conversion

Frequency is automatically detected(1)%%(Apparent power/active power)

5 cycles
0.8 (lag)
105 or more
105 or more
200/800
Lithium-ion battery (LIB)
100/200/
50/100/30/60/
300/400
150/200
90/120
45 or
46 or
46 or
less
less
less
51 or
55 or
55 or
less
less
less (2)-20 to +55
10 to 90
-20 to +55

Variation range 0.7 (lag) to 1.0
Auto switching to bypass circuit (1)200 ms30-second period / 2 cycles
Ambient temperature 25˚C, at rated output
Default value
1 m from front of device, A-weighting(Where the ambient temperature is 40˚C or lower)
1 m from front of device, A-weighting(Where the ambient temperature exceeds 40˚C)(3)

Non-condensing(4)(1) The inverter synchronizes operation with AC input and allows switchover without interruption through a bypass circuit provided that the
AC input frequency is within a range of the rated frequency ±3% (able to be switched between 1, 3, 5 and 7%), and the AC input voltage
is within the rated voltage ± 20% (if the load level is less than 70%: between -40% and +20%). Note that operation changes to battery
operation when the AC input frequency exceeds the setting range.
(2) 60 dB or less when battery voltage drops.
(3) Battery charging stops when battery temperature exceeds 55˚C.
(4) To prolong battery life, avoid use or storage for extended periods of time in environments exceeding +30˚C. If the UPS is stored without
being operated for a long period, the batteries may require recharging once a year.

SANYO DENKI Technical Report No.44 November 201730

Table 2: The SANUPS N11B-Li series specifications
Item

Unit

Model
Rated output capacity
UPS topology
Type

AC input−kVA/kW−

Cooling system−

Inverter system−

No. of phases/wires
Rated voltage
Voltage range
Rated frequency

−

V
%
Hz

Frequency range%

Required capacitykVA

No. of phases/wires−

Single-phase 2-wire

Rated voltage

V100, 110, 120

2.1 or lessApparent power/active power

Commercial synchronous online double
conversion
Same as output voltage
Frequency is automatically detected(The fluctuation range is the same as theselected output frequency accuracy)
Max. capacity during battery recovery
charging
Voltage waveform during battery
operation: Sine wave%

Rapid loadchange%Within ± 7 of rated voltage

Duringpower outage,
recovery%Within ± 5 of rated voltage

During battery operation, at rated output−

Variation range 0.7 (lag) to 1.0−

0.8 (lag)
Output breaker trip
105 or more
200/800
Lithium-ion battery (LIB)

Minute150%

Rated frequency

Hz

Frequency accuracy%

AC output
Voltage harmonic distortion
Transientvoltagefluctuation

1.4 or less

Remarks

During commercial operation:
Same as input power source
During battery operation:
Within ± 2 of rated voltage
50/60
During commercial operation:
Same as input power source
During battery operation:
Within ± 0.5 of rated frequency
3 or less/7 or less

Voltage accuracy

Power factor
Overcurrent protection
Inverter
Overload
capability Bypass
Type
Battery

Ratings and characteristics
N11BL102
N11BL152
1/0.8
1.5/1.2
Passive standby
Passive
Forced air cooling during battery operationand high temperatures
High-frequency PWM method(during battery operation)
Single-phase 2-wire
100, 110, 120
Within ± 10 of rated voltage
50 or 60
Within ± 1, 3, 5, or 7of rated frequency

Backup time

Acoustic noise
IP ratingAmbient temperature
Operatingenvironment Relative humidity
Storage environment

%
%

dB
−

˚C
%
˚C

40 or less43 or less
IP65
-20 to +50
10 to 90
-20 to +55

At rated output
Same as the input frequency

At rated output
During battery operation, at rated output
During battery operation, for 0 ⇔ 100%load step changes /output switch

200 ms
30 s / 2 cycles
Ambient temperature 25˚C, at rated
output, default value
1 m from front of device, A-weighting(1)

Non-condensing(2)(1) Battery charging stops when battery temperature exceeds 55˚C.
(2) To prolong battery life, avoid use or storage for extended periods of time in environments exceeding +30˚C. If the UPS is stored without
being operated for a long period, the batteries may require recharging once a year.

31

SANYO DENKI Technical Report No.44 November 2017

Development of the Small-Capacity UPS SANUPS A11K-Li and SANUPS N11B-Li Series

6. Advantage for Customers
Below is a list of customer advantages gained by adopting

7. Conclusion
Moving for ward, information and com munication

this device.

technologies will undergo even further sophistication and(1) Common to the SANUPS A11K-Li and SANUPS

play an even more important role in society. Moreover, with

N11B-Li

increased applications in a variety of environments, it is1) Broader selection of applications and installation

likely that the requirements for UPS will diversify.

environments due to a wider operating temperature
range2) Re duc e d m a i nten a nc e c o st s t h a n k s to lowmaintenance batteries3) In the unlikely event of a problem, maintenancework can be performed without interrupting power

We will continue to quickly develop products to meetthese market demands and provide devices that fulfill ourcustomers’ needs.
We w ish to express ou r deep appreciation to themany people who cooperated and offered advice in thedevelopment and production of these UPSs.

supply to the load equipment.
(2) The SANUPS A11K-Li
1) More freedom of installation environment due toless required installation space.
2) Can perform backup safely even when power source

References
Kazuya Yanagihara and Others: “Development of the Small-Capacity
UPS SANUPS A11K Series”, SANYO DENKI Technical Report No.40(2015)

is unstable thanks to its wide input voltage range.
(3) The SANUPS N11B-Li
1) Backs up power for outdoor equipment.
2) Sealed structure enables use in environments
exposed to dust and rain.

SANYO DENKI Technical Report No.44 November 201732

Development of the Small-Capacity UPS SANUPS A11K-Li and SANUPS N11B-Li Series

33

Yuhei Shoyama

Hirofumi Kimura

Joined SANYO DENKI in 2009.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Joined SANYO DENKI in 2007.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Shinichiro Yamagishi

Takeo Murai

Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Joined SANYO DENKI in 2012.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Yoshitsugu Kashiwagi

Kazuya Yanagihara

Joined SANYO DENKI in 1989.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Joined SANYO DENKI in 2013.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Yasuhiko Ogihara

Shota Ozawa

Joined SANYO DENKI in 1991.
Power Systems Div., Design Dept. 2
Works on the mechanism and design of UPS.

Joined SANYO DENKI in 2014.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Naoki Shiratori

Hiroyuki Saito

Joined SANYO DENKI in 1992.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

Joined SANYO DENKI in 2015.
Power Systems Div., Design Dept. 2
Works on the mechanism and design of UPS.

Hidenori Takizawa

Kazuya Hiraguri

Joined SANYO DENKI in 1997.
Power Systems Div., Design Dept. 2
Works on the mechanism and design of UPS.

Joined SANYO DENKI in 2016.
Power Systems Div., Design Dept. 2
Works on the development and design of UPS.

SANYO DENKI Technical Report No.44 November 2017

New Products Introduction

Development of the SANUPS P73L
PV Inverter with a Peak Cut Function
Tetsuya Fujimaki

Takeshi Hama

Yuzo Kubota

Makoto Ishida

Masahiro Inukai

Masahiro Uchibori

1. Introduction

Takashi Kobayashi

2.2 Circuit configuration
and basic operations

Since the Great East Japan Earthquake, there is an

Figure 1 shows the appearance of the SANUPS P73L

increasing demand for local governments and private

grid-connected, isolated, charging type and grid-connected,

businesses to install backup power sources in preparation

isolated type. Figures 2 and 3 show the block diagrams forfor prolonged power outages during disasters. Of thethe grid-connected, isolated, charging type and the grid-

available systems, power generation systems combining PV

connected, isolated type respectively.

panels and Li-ion storage batteries are attracting interest

The grid-connected, isolated, charging type is comprised

due to their numerous advantages, such as the abilityof a PV inverter unit, charging unit and I/O box. The grid-

to be used as a “local-production, local-consumption”

connected, isolated type is comprised of a PV inverter unit

decentralized power source during disasters to minimize

and I/O box. The PV inverter unit is common with that ofpower consumption during peak times.

the grid-connected, isolated, charging type.

SANYO DENKI already offers the SANUPS P73K

The grid-connected, isolated, charging type supports

as a PV inverter with a peak cut function supporting

peak power cut by supplying the power of its PV panel andLi-ion storage batteries. However, now we have developed

storage battery to a general load via the isolated converter

the SANUPS P73L, which maintains the functions andcircuit and inverter circuit equipped in the PV inverter unit.

performance of the SANUPS P73K while gaining functions

Moreover, it can supply AC power to the isolated operationthat further meets market demands. This article will

output during power outages on the grid. The charging unit

introduce the features of this new product.

controls the charging and discharging of the storage battery
through a bi-directional converter circuit. The I/O box has

2. Overview and Featuresof the SANUPS P73L

an isolated operation output bypass breaker and can switch

2.1 System configuration from 10 to 60 kW

measures the power grid.

between power circuits. It automatically starts and stops
peak cut through the input of a power transducer signal that

The SANUPS P73L is comprised of a 10 kW PV inverter

The grid-connected, isolated type supplies the power

unit, 10 kW charging unit and I/O box, with the ability toof its PV panel to a general load and the power grid via

add up to six 10 kW PV inverters as a scalable system. This

the isolated converter circuit and inverter circuit in the

product comes in the “grid-connected, isolated, charging

PV inverter unit. Moreover, it can supply AC power to thetype” and “grid-connected, isolated type,” with output

isolated operation output during power outages on the grid.

capacities ranging from 10 to 60 kW.

The I/O box has an isolated operation output bypass breakerand can switch between power circuits.

SANYO DENKI Technical Report No.44 November 201734

30 kW grid-connected,
isolated, charging type

30 kW grid-connected,
isolated typeFig. 1: The SANUPS P73L

Fig. 3: Block diagram for the grid-connected,
isolated type

2.3 Parallelizationof isolated operation output
The existing model, the SANUPS P73K, has an isolated
operation output capacity of up to 10 kVA. However, in the
new model, the SANUPS P73L, the circuit configurationof the isolated operation output has been revised andby enabling parallel operation capacities to the isolated
operation output, it has become possible to supply power up
to 60 kVA. With the SANUPS P73L, it is possible to offer
more flexible proposals meeting needs for systems requiring
isolated operation
output capacities exceeding 10 kVA.
図版の文字
123

英語版用
2.4 Single circuit
connection
Condensof the PV panel input

The PV panel input for the existing model SANUPSP73K require an input circuit for every 10 kW, and thus
wiring for multiple circuits in total. Multi-circuit wiringFig. 2: Block diagram for the grid-connected,
isolated, charging typehas the disadvantages of an increased number of wires
and complicated installation due to the need to wire PV
panel inputs to the I/O box terminal blocks individuallyfor each 10 kW. However, the new SANUPS P73L enriches
the lineup with the added specification of single circuit
connection for the PV panel input, thus making wiring workeasy.

2.5 Benefits of a bi-directional converter
Just as the SANUPS P73K, the SANUPS P73L gridconnected, isolated, charging type is equipped with a bidirectional converter in its storage battery input. The bidirectional converter eliminates the need to make the PV
panel and storage battery voltages equal, thus reducing

35

SANYO DENKI Technical Report No.44 November 2017

Development of the SANUPS P73L PV Inverter with a Peak Cut Function

overall system cost.

P73L

PV panel

Furthermore, for PV inverters with a circuit type based on
direct connection between the PV panel and storage battery,Loadfor power
outage use

Commercial
power

the PV panel’s operating point is the terminal voltage ofthe storage battery, therefore MPPT control is not possible.
However, with the newly-developed control method adopted

General loadon the SANUPS P73L, it is possible to maximize the PV
panel output through maximum output tracking control
even during charging/discharging of the storage battery orPowertransducer

Storagebattery

Fig. 4: Grid-connected operation mode

isolated operation. As such, the power generation amount is
expected to increase significantly.

3.2 Peak cut operation mode
2.6 Function to switch
to isolated operation mode
In regards to switching to isolated operation mode,

PV panel 5 shows
Figurethe f low of power during peak cut
P73L
Load

power is activated when
operation mode. Peak cut operationformodeoutage use

Commercial
power

all of the following conditions are met.

the SANUPS P73L has been equipped with switchover•

Schedule settings start peak cut operation mode

functions that can be activated manually, automatically, and•The power grid is normal

remotely.

•PowerT he power being received fromthe
Generalloadpower grid exceeds

This makes it possible to propose more flexible systems.

3. The SANUPS P73L Operation Modes

transducer

a pre-set value

Storage• T he remaining capacity of the storage battery is above abattery

set value

PV panel peak cut
Duringoperation mode, the SANUPS P73L
P73L
Load

The SANUPS P73L has the following four operation

power
converts DC power generated by forPVpanels and storage

modes: grid-connected operation mode, peak cut operation

Commercial
batteries into AC power, adjusts voltage, and synchronizes

mode, charging operation mode and isolated operation

PV panel to connect
frequency
P73Lwith the grid, enabling AC power to bemode. Below is a description of each operation mode.

for power the increase insupplied to a general load. This suppresses

outage use

power

Load

the received power.

3.1 Grid-connected operation mode
Figure 4 shows the flow of power during grid-connected
operation mode. Grid- connected operation mode isactivated when all of the following conditions are met.
•

Schedule settings start grid-connected operation mode•

The PV panel power exceeds a set value•

The power grid is normal

Also, commercial power is supplied to the load for power
batteryPower
In such case, if the received power
being
from theGeneralload received
transducer

power grid is below the pre-set value, the PV inverter will
Storagestopdischarging the storage battery.
battery

PV panel

P73L

P73L converts the PV panel-generated DC power into
PV panel

P73L

connect with the grid, enabling the AC power to be supplied
to the grid. Moreover, the PV inverter performs MPPT

Loadfor power
outage use

if the PV-generated power is larger than the general load

Commercial
Power
power
transducer

General load

Powertransducer

Storagebattery

Fig. 5: Peak cut operation mode

power consumption, this product sends the surplus power tothe grid.
Also, commercial power is supplied to the load for power
outage use via a bypass circuit.

Commercial
power

Load
for power
outage use
General load

control and supplies AC power to the power grid dependingon the amount of the PV-generated power. In such case,Power
Commercial
transducer
power

Storageuse via a bypass circuit.
outageDuring grid-connected operation mode, the SANUPSAC power, adjusts voltage, and synchronizes frequency tooutage use
General load

Storagebattery
PV panel

P73L

Load
for power
outage use

General load

Commercial
power

Power
transducer

SANYO DENKI Technical Report No.44 November 2017

Storagebattery36

power

General load

StoragebatteryPowertransducer

Storagebattery

3.3 Charging operation mode

連系運転

PV paneloutageuse. In suchcase, the power of the storage battery is
P73L
Load

Figure 6 shows the f low of power during charging

for power
supplied to the load for power outage
use even when there

operation mode. Charging operation mode is activated when

Commercial
is no sunlight. Meanwhile, if the power generated by
the PV

all of the following conditions are met.

panel is larger than the power supplied to the load for power

The power grid is normal

power

outage use, the surplus power will be used to charge the•PV Schedulepanel
settings
P73L start charging operation mode•

outage use

Loadfor power
outage use

storage battery.

General load

Powertransducer

Commercial
During charging operation mode, the SANUPS
P73L

Also, in cases of ongoing isolated operation due toconverts commercial AC power into DC power and charges

Storageprolonged
power outages, if Condens
the DC voltage falls below athe storage battery with the power specified using theset value due
to a decrease in 英語版用
storage battery power, the PV
ピークカット運転

power

Power
schedule function. Power from General
the PV
loadpanels supplementtransducer

the charging commercial power, and if PV panel power is

英語版用

battery

Times Teninverter will stop isolated operation in order to protect thestorage battery.

Storagethan the charging power, it will be supplied to thelargerbattery

grid.

P73L

PV panelAlso, commercial power is supplied to the load for power
outage use via a bypass circuit.
P73L

PV panelLoadfor power
outage use

General load

Load
for power
outage use

General load
Commercial
power

Fig. 6: Charging operation modePowertransducer

Storagebattery

Fig. 7: Isolated operation modePowertransducer

Storagebattery

Commercial
power

充電運転

3.5 Switching to each operation mode
Figure 8 shows the switchover to each of the operation
modes: grid-connected operation mode, peak cut operationmode, charging operation mode, and isolated operation

P73L
3.4 Isolated operation
modeLoad
PV panelfor powerisolated operation
Figure 7 shows the flow of power during

Through schedule settings, automatic switchover to grid-Commercial
mode. Isolated operation mode is activated when allof thepower

connected operation mode, peak cut operation mode, orI solated operation mode is enabled v ia ma nua l

The automatic switchover function for isolated operationPowerswitchover, automatic switchover,or remoteswitchover.
General loadtransducer

mode automatica l ly sw itches to isolated operation

outage use

following conditions are met.
••T he remaining capacity of the storage battery is above a

Storageset value
battery

During isolated operation mode, the DC power of the

PV panel and storage battery is converted to AC power

37

mode.

charging operation mode can be performed.
自立運転

mode when a power grid outage is detected. The remoteswitchover function for isolated operation mode switches theoperation mode to isolated operation mode with an isolated
operation command inputted from an external contact.

while voltage adjustment and waveform conditioning

Both the manual and automatic switchover functions

are performed, and AC power of a constant-frequency,

can be selected with PV inverter unit settings. The remoteconstant-voltage sine wave is supplied to the load for powerswitchover function is valid when manual switchover is set.

SANYO DENKI Technical Report No.44 November 2017

Development of the SANUPS P73L PV Inverter with a Peak Cut Function■ Grid-connected mode
PV panel■ Peak cut mode
Load forpower outage
use

General load

PV panel
Commercial
power

Power
transducer

Load forpower outage
use

General load

Commercial
power

Power
transducer

Storage battery

Storage battery

図版

123

英語

■ Charging mode
PV panel

Cond■ Isolated mode
Load forpower outage
use

General load

英語

Time

PV panel
Commercial
power

Commercial
power

Power
transducer
Storage battery

Storage battery

Schedule setting

Manual, automatic, or remote switchover

Fig. 8: Switching to each operation mode

4. Specifications
Table 1 shows the electrical specifications of the SANUPSP73L PV inverter with peak cut function (grid-connected,
isolated, charging type), while Figure 9 shows its external
dimensions.
Table 2 shows the electr ical speci f ications of the
SANUPS P73L PV inverter with peak cut function (gridconnected, isolated type), while Figure 10 shows its external
dimensions.

SANYO DENKI Technical Report No.44 November 201738

Table 1: Electrical specifications of the SANUPS P73L grid-connected, isolated, charging type
Item
Model
Rated output capacity
Main circuit type
Switching method
PV input
Isolation
methodBattery input
Cooling method
Rated voltage
Maximum allowable
input voltage
PV input
Input operating
voltage range
Maximum power point
tracking range
Fluctuation range
Battery
input/output

Max. charge/
discharge power*
Charging voltage

Grid output

Rated voltage
Rated output current
Rated frequency
No. of phases/wires
Output current
harmonic distortion
Output power factor
Rated output
No. of phases/wires

Isolated
operation
outputRated voltage
Voltage accuracy
Rated frequency
Frequency accuracy
Output voltage
harmonic distortion
Overload capability

Efficiency
Grid protection
Islandingdetection

Passive method
Active method

Communication
Operatingenvironment

Ambient temperature
Relative humidity
Altitude

Paint color
Heat dissipation
Received-power measurement function
Mass

P73L103P
P73L203P
P73L303P
10 kW
20 kW
30 kW
Self-commutated voltage typeHigh-frequency PWM
High-frequency isolation typeNon-isolation type
Forced air cooling
400 VDCP73L503P
50 kW

P73L603P
60 kW

10 kW x 5
circuits

10 kW x 6
circuits

570 VDC
150 to 570 VDC (rated output range: 250 to 540 VDC)
190 to 540 VDC
200 to 400 VDC
10 kW x 1
circuit

10 kW x 2
circuits

10 kW x 3
circuits

10 kW x 4
circuits

Factory settings: 296 VDC,
Adjustment range: 200 to 400 VDC (1 V increments) (rated range: 250 to 400 VDC)
202 VAC28.6 AAC
57.2 AAC
85.7 AAC
114.3 AAC
142.9 AAC
171.5 AAC
50/60 Hz3-phase 3-wireTotal current: 5% or less, individual harmonic order: 3% or less0.95 or greater (at rated output, power factor 1.0 setting),
power factor setting range: 0.8 to 1.0 (0.01 increments)
10 kVA
20 kVA
30 kVA
40 kVA
50 kVA
60 kVA
(at 1.0 p.f.)(at 1.0 p.f.)(at 1.0 p.f.)(at 1.0 p.f.)(at 1.0 p.f.)(at 1.0 p.f.)3-phase 3-wire(possible to convert to single-phase output using the optional Scott-connected transformer)
202 VAC
Within ± 8% of rated voltage
50/60 Hz
Within ± 0.1 Hz of rated frequency
Linear load: 5% or less
100% continuous
93% (at grid-connected operation mode,with efficiency measurement method in accordance with JIS C 8961)
Overvoltage (OVR), undervoltage (UVR), overfrequency (OFR), underfrequency (UFR)
Voltage phase jump detection
Reactive power variation method
RS-485-10 to +40˚C
30 to 90% max. (No condensation)
1000 m or lower
Munsell 5Y7/1 (semi-gloss)
1100 W
2200 W
3300 W
4400 W
5500 W
6600 W
Yes, 4 to 20 mA
190 kg
290 kg390 kg
580 kg705 kg780 kg* Maximum current 40 ADC

39

P73L403P
40 kW

SANYO DENKI Technical Report No.44 November 2017

Development of the SANUPS P73L PV Inverter with a Peak Cut Function

Table 2: Electrical specifications of the SANUPS P73L grid-connected, isolated type
Item
Model
Rated output capacity
Main circuit type
Switching method
Isolation
PV inputmethodCooling method
Rated voltage
Maximum allowable
input voltage
PV input
Input operating
voltage range
Maximum power
point tracking range
Rated voltage
Rated output current
Rated frequency
No. of phases/wires
Grid output
Output current
harmonic distortion

Passive method
Active method

Communication
Operatingenvironment

Ambient temperature
Relative humidity
Altitude

Paint color
Heat dissipation
Received-power measurement function
Mass

142.9 AAC

171.5 AAC

570 VDC
150 to 570 VDC (rated output range: 250 to 540 VDC)
190 to 540 VDC
202 VAC28.6 AAC
57.2 AAC
50/60 Hz3-phase 3-wire

85.7 AAC

114.3 AAC

Total current: 5% or less, individual harmonic order: 3% or less

10 kVA
(at 1.0 p.f.)

Grid protection

P73L603S
60 kW

Forced air cooling
400 VDC

Rated output

Rated voltage
Voltage accuracy
Rated frequency
Frequency accuracy
Output voltage
harmonic distortion
Overload capability

P73L503S
50 kW

High-frequency isolation type0.95 or greater (at rated output, power factor 1.0 setting)power factor setting range: 0.8 to 1.0 (0.01 increments)

Efficiency

Islandingdetection

P73L403S
40 kW

Output power factor

No. of phases/wires
Isolated
operation
outputP73L103S
P73L203S
P73L303S
10 kW
20 kW
30 kW
Self-commutated voltage typeHigh-frequency PWM

20 kVA

(at 1.0 p.f.)*

30 kVA

(at 1.0 p.f.)*

40 kVA

(at 1.0 p.f.)*

50 kVA

(at 1.0 p.f.)*

60 kVA

(at 1.0 p.f.)*3-phase 3-wire(possible to convert to single-phase output using the optional Scott-connected transformer)
202 VAC
Within ± 8% of rated voltage
50/60 Hz
Within ± 0.1 Hz of rated frequency
Linear load: 5% or less
100% continuous
93% (at grid-connected operation mode,with efficiency measurement method in accordance with JIS C 8961)
Overvoltage (OVR), undervoltage (UVR), overfrequency (OFR), underfrequency (UFR)
Voltage phase jump detection
Reactive power variation method
RS-485-25 to +60˚C (Operates with derated output above 40˚C)
30 to 90% (No condensation)2000 m or lower
Munsell 5Y7/1 (semi-gloss)
760 W
1520 W
2280 W
3040 W
3800 W
4560 WNone
145 kg
220 kg295 kg440 kg540 kg590 kg* Model with 10 kVA isolated operation output is also available.

SANYO DENKI Technical Report No.44 November 2017

40

1550

1250

650

650

650

10 kW

20 kW

30 kW

125

125

125

125

125

400

950
300

1250

1550

250

Depth:650

650

650

650

40 kW

650
50 / 60 kW

Fig. 9: External dimensions of the SANUPS P73L grid-connected, isolated, charging type

650

1300
650

30 kW

650

125

1000

1300
650
20 kW

125

650
10 kW

125

1000
125

125

700
400
300

Depth:650

650

40 kW

650

50 / 60 kW

Fig. 10: External dimensions of the SANUPS P73L grid-connected, isolated type

5. Conclusion
This article has briefly introduced the overview and
Depth:650
featuresof the SANUPS P73L PV inverter with peak cut

function.
1550

1550

1250

950
300

expected to contribute to fields such as environmental

1250

250

I n addition to improving operating rate of power
equipment by reducing peak demand, this product is

400

conservation through effective utilization of natural energy

650

650

650

products, this new product is expected to enable the building
10 kW
20 kW
30 kW
of optimal systems
and be introduced
to a wider market.

SANYO DENKI will continue swift product development
responding to these fields to provide products which win
customer satisfaction and contribute to the realization of alow-carbon society.
We wish to express our appreciation to all those who
cooperated and offered advice in the development andproduction of this product.

41

SANYO DENKI Technical Report No.44 November 2017125

as a PV inverter with even richer functions than existing

125

125

125

125

and emergency power source during disasters. Moreover,
650

650
40 kW

650

650
50 / 60 kW

Development of the SANUPS P73L PV Inverter with a Peak Cut Function

Tetsuya Fujimaki
Joined SANYO DENKI in 2011.
Power Systems Div., Design Dept. 1
Works on the development and design of PV
power systems.

Takeshi Hama
Joined SANYO DENKI in 1986.
Power Systems Div., Design Dept. 1
Works on the development and design of PV
power systems.

Yuzo Kubota
Joined SANYO DENKI in 1983.
Power Systems Div., Design Dept. 1
Works on the mechanism and design of PV
power systems.

Takashi Kobayashi
Joined SANYO DENKI in 1995.
Power Systems Div., Design Dept. 1
Works on the development and design of PV
power systems.

Makoto Ishida
Joined SANYO DENKI in 2006.
Power Systems Div., Design Dept. 1
Works on the development and design of PV
power systems.

Masahiro Inukai
Joined SANYO DENKI in 2009.
Power Systems Div., Design Dept. 1
Works on the development and design of PV
power systems.

Masahiro Uchibori
Joined SANYO DENKI in 2013.
Power Systems Div., Design Dept. 1
Works on the development and design of PV
power systems.

SANYO DENKI Technical Report No.44 November 201742

Feature: Technologies Offering Value in New Fields

Servo Systems Products Offering
Value in New Fields
Yasushi Misawa

Nobuo Arakawa

Yoshiyuki Murata

1. Introduction
Research and development of “service robots” is being
promoted to tackle the problem of Japan’s shrinking

Masao Mizuguchi

Yoshihiro Shojitypes have their pros and cons but this article will introduce
the SANMOTION R series 20 mm sq. AC servo motor as acompact cylindrical servo motor achieving high output, lowloss, and weight reduction.

workforce and increased social insurance costs caused

Figure 1 shows an external view of the compact 20 mm sq.

by a declining birthrate and aging population. Service

AC servo motor, while Table 1 shows its main specifications.

robots are expected to advance into various applications

To increase output and minimize loss and weight, we

including medical, security, nursing, welfare, and customer

employed coupled analysis of optimization support tools

service. Servo Systems products used in these fields mustand electromagnetic field simulation to solve the conflicts

not only be compact, lightweight, and wire-saving, but

between improving motor characteristics and reducing

also reduce power supply voltage and power consumption

weight.

while enabling multi-axis systems. Moreover, there is also a(1) High output

need to support a fieldbus capable of high-speed, real-timeThrough optimization of the core profile and magnet,

control of multiple axes, and controllers for their batch

this product has 17% higher peak torque compared

control.

to our existing product. This contributes to the size

This article will introduce products and systems that canbe used in such fields.

reduction and high-load drive of equipment.
(2) Low loss
By applying high-space factor winding technology

2. Servo Systems Products
for Service Robots

in which the magnet wire is mechanically bent then

2.1 48 VDC compact 20 mm sq.
AC servo motorby 34% compared to our current model. Loss reduction

For the configuration of compact, lightweight, andhigh-output servo motors, the design must either be

inserted into the core, copper loss is significantly
reduced to achieve low loss. Loss has been decreased
helps minimize temperature rise in motors, decreasing
device heat emissions.
(3) Lightweightsmall-diameter, long, thin cylinder or a flat, thin disc. The

We reduced weight by using a frame with a roundcompact cylindrical type is structured the same way as

cross-section and eliminating the corners of thegeneral servo motors, therefore the basic design is simple.

frame which did not contribute to the magnetic path.

However, the core, winding, and magnet must be arranged

The result was 8.5% less weight compared to thein a limited space, so some creative maneuvering wascurrent model. A lighter motor contributes to lighter

necessary to increase output and reduce loss. Meanwhile,

equipment.

the flat type can be designed with a large torque area,

43

therefore high output is easily achieved; however, theThis product can also be used in mobile service robots

motor’s magnetic circuit is complicated, so we creatively

thanks to its 48 VDC support, and its compact, lightweight,

arranged the core, bearings, and other components. Bothhigh output, low heat generating, and power saving design.

SANYO DENKI Technical Report No.44 November 2017

Servo Systems Products Offering Value in New Fields

With its multi-axis design, this product has achieved 40%
volume reduction and 60% weight reduction compared withfour single-axis servo amplifiers. Furthermore, throughcommon use of the power circuit and general-purpose
I/O circuit, and the built-in daisy chain connection circuit
for host communication, we have significantly reduced
the number of power cables and cables used for I/O andcommunication, thus contributing to a smaller footprint.
Moreover, by minimizing heat generation with built-in heatradiator fins and a cooling fan (RF2K24A only), the new

Fig. 1: Compact 20 mm sq. AC servo motor

product improves the device’s thermal management.
From a safety perspective, Safe Torque Off (STO)
function has been standardly equipped with this product.

Table 1: Main specificationsof the compact 20 mm sq. AC servo motor

All four axes can be controlled via safety circuit. As a result,

Model number

this product has been certified with a high safety level

R2GA02D20F

R2GA02D30F(SIL3 for IEC 61508, PL=e for ISO 13849-1) with the same

Flange size

20 mm sq.

20 mm sq.

2-input/1-output design as a single axis amplifier, meaning it

Input power

48 VDC

48 VDCcan be used in fields such as medical and nursing where highRated output

20 W

30 W

safety performance is required.

Rated speed
Maximum rotational
speed
Rated torqueContinuous stall
torque3,000 min-1

3,000 min-1

6,000 min-1

6,000 min-1

0.064 N･m

0.095 N･m

0.064 N･m

0.095 N･mPeak stall torque0.23 N･m

0.38 N･m

Motor mass

0.14 kg

0.18 kg

Encoder (standard)

MA018

MA018

Encoder resolution

13 bit13 bitServo amplifiermodel number

Pulse input, single-axis
RF2G21A0A00
EtherCAT, single-axis
RS2K04A2HL5 / RS2K04A2HA5EtherCAT, multi-axis
RF2J24A0HL5 / RF2K24A0HL5

The fieldbus between the controller and servo amplifieris EtherCAT, which SANYO DENKI has used for sometime. With a communication speed of 10 0 Mbps andminimum communication cycle of 125 µs, this productachieves excellent real-time performance and high-accuracy
synchronization. Moreover, the position assist function cancompensate the position feedback of two axes to further
improve synchronization accuracy.

2.2 24/48 VDC, 4-axis integrated servo
amplifier with EtherCAT interface
This section will introduce the 4-axis integrated servo
amplifier equipped with an EtherCAT interface.
Figure 2 shows the appearance of the 4-axis integrated
amplifier while Table 2 shows its main specifications. Thisamplifier has an input power of 24 or 48 VDC to enable
battery-powered drive, therefore it can be used in mobile
service robots. Also, by sharing a common power circuit,regenerative power of a motor can be used to power othermotors, contributing to energy savings.

Fig. 2: Appearanceof the 4-axis integrated servo amplifier

SANYO DENKI Technical Report No.44 November 201744

Table 2: Main specifications of the 4-axis integrated servo amplifier
Model number

RF2J24A
0.75 kg

Mass

200 H x 50 W x 130 D mm

Dimensions
Input power

Control power

24 VDC ± 10%

Main circuit power

48 VDC ± 10% or 24 VDC ± 10%

Compatible motor

20 mm sq.
40 mm sq.
(20 to 30 W)

20 mm sq.
40 mm sq.
60 mm sq.
(20 to 200 W)

Output limit per axis

30 W or less

200 W or lessTotal output of 4 axes

120 W or less
300 W or less
EtherCAT
Minimum communication cycle: 125 µs
Position assist, torque assist
Inputs: 8 (common to 4 axes)
Outputs: 8 (2 outputs per axis)
Safe Torque Off (STO)
IEC 61508: SIL3
IEC 62061: SILCL3
ISO 13849-1: PL=e

Basic specifications

Host interface
Assist function
Function

General-purpose I/O
Safety functions
Safety performance level2.3 24/48 VDC, 4-axis integrated
closed-loop stepping driverwith EtherCAT interface
This section introduces the 4-axis integrated closed-loop
stepping system equipped with an EtherCAT interface.

as standard to achieve smooth control. Furthermore, thisproduct supports the battery-less absolute encoder, Model
No.HA035(HA035). HA035 does not require a battery forretaining multi-turn data so it reduces maintenance while
being environmentally friendly. If HA035 is used, there is

Our SANMOTION Model No.PB series closed-loop

no need to wire in a limit sensors or homing sensor. Homing

stepping system does not step-out. This system does notsequence is also unnecessary, delivering new value throughrequire complicated adjustments, therefore it is suitable forshort system boot times.

such peripherals as a robot’s auxiliary axes.

45

RF2K24A
0.8 kgCustomers can choose from two control types: closed-loop

Figure 3 shows the appearance of a closed-loop stepping

control and low-deviation closed-loop control. The former

motor and 4-axis integrated PB driver, and Table 3 provides

offers energy-saving and smooth operation, producing

the main specifications of the driver. The advantages of aminimal torque, noise, and heat, making it suitable forcompact and wire-saving design resulting from the 4-axis

applications that require human interaction such as medical

integrated structure are as stated in the servo amplifierand nursing fields. Moreover, closed-loop control systems

section. In addition, as with the 4-axis integrated servo

can push at a constant force, thereby replacing a pneumatic

amplifier, the input power is either 24 or 48 VDC to enableactuator to of fer f u r ther si mpl i f ication of systems.

the battery-powered drive. Moreover, the power supply

Meanwhile, the low-deviation closed-loop control is suitableconnector and the pin arrangement are common with thefor applications requiring minimal position command delay,

servo amplifier, therefore the same harness can be used.

trajectory control with multiple axes and synchronizedPreviously, encoders were mounted to a stepping motor

operations. By refreshing position commands with a 250 µs

to monitor step-out, therefore the emphasis was on low

minimum communication cycle, and maximizing thecost rather than high resolution. Nowadays, however, aperformance of synchronous stepping motors, high-speed

16,000 P/R high-resolution incremental encoder comes

and accurate motion can be obtained.

SANYO DENKI Technical Report No.44 November 2017

Servo Systems Products Offering Value in New Fields

control function and kinematics to support various robot
mechanisms, allowing customers to easily build robots
themselves.
To improve the drive quality of equipment, we increased
the command refresh cycle speed of servo amplifiers forsmoother control. Our lineup of products enable complex
operation of multiple robots by increasing the number ofcontrollable motor axes. Moreover, with a 24 VDC input,
the controller can be battery-driven, making it appropriate
for mobile service robots. Additionally, we use an open
network EtherCAT as the motion network therefore adifferent drive units can be combined and used, suchas EtherCAT-compatible servo amplifiers and stepping
drivers, making it possible to select and use the optimal

Fig. 3: Appearance of a stepping motorand 4-axis integrated closed-loop stepping driver

servo system.
Figure 4 is the appearance of the SANMOTION C and the
below section introduces its features.

Table 3: Main specificationsof the 4-axis-in-one type PB driver
Model number

Basicspecifications

Function

PB4D003E440

Mass

0.7 kgDimensions
Control
power
Input
Main
power
circuitpower

160 H x 60 W x 95 D mm
24 VDC ± 10%
48 VDC ± 10% or
24 VDC ± 10%

Compatible
motor

28 mm sq.
42 mm sq.
60 mm sq.

Compatible
encoder

16000 P/R incremental
encoder or absolute encoder(28 mm sq. only supports 2000
P/R incremental encoders)

Host interface

EtherCAT
Minimum communication
cycle time: 250 µs

motion control, and robot control functions. The control
and robot control so the SA NMOTION C supports

Control method

Closed-loop control,
Low-deviation closed-loop
control

General-purpose
I/O

Inputs: 16 (4 inputs per axis)
Outputs: 12 (3 outputs per
axis)

user’s application.

Fig. 4: Appearance of high-speed processing
controller SANMOTION C(1) Control function
The SANMOTION C is equipped with PLC control,
and programming methods differ between motion control
both by having various runtime firmware and integrated
development tool software to choose from depending on(2) Motion control
By using the various standardized MFB (motion function

2.4 The 24 VDC high-speed processing
controller SANMOTION C

block), anyone can write a motion control program withease. Table 4 provides details of the motion control function.

The SANMOTION C is a motion controller for servodriven industrial machinery. It can control a servo amplifierand closed-loop stepping dr iver th rough a network
for motion control, thereby controlling the position,
speed, and torque of a servo motor and stepping motor.
Furthermore, the SANMOTION C is equipped with a robot

SANYO DENKI Technical Report No.44 November 201746

Table 4: Motion control function
No. of controlled axes Max. 64
Communication cycle
1 to 8 mstime
Position control (PTP), speed control,
Control method
torque control
Acceleration/
deceleration method

Automatic trapezoidal acceleration/
deceleration, S-shaped acceleration/
deceleration

Unit for positioning
control

Arbitrary (pulse, mm, inch, degree)

Max. command value
Programming
language-2147483648 to 2147483647(32-bit signed)
Complies with IEC 61131-3(IL, ST, LD, FBD, SFC, CFC)

Homing, incremental mode,
Motion function block absolute mode, constant speed mode,
electronic cam, electronic gear

• Basic command processing time:

The shortest processing time for basic commands(floating point arithmetic commands) is 11 ns.
• Maximum no. of controlled axes:

Up to 64 axes can be controlled.
• Multiple robot control:

Capable of driving up to two 6-axis articulated robots.

Table 6: Control performance when combinedwith our servo amplifier equippedwith an EtherCAT interface
Control
performance
Basic commandprocessing timeMax. no. ofcontrollable axes

(3) Robot control
By supporting kinematics for various mechanisms andby using original robot language, robot orientation and
TCP (tool center point) position can be controlled. Table 5

No. of controlled
robots(6-axis articulated
robots)

Product model
Communication
cycle time
SMC263X
SMC265X
−

18 ns

11 ns

4 ms

64

64

2 ms

32

64

1 ms

16

32

8 ms

2 units

2 units

4 ms

1 unit2 units

2 ms−

1 unitprovides details of the robot control function

Table 5: Robot control function
No. of controlled axes
(for each robot)
Communication cycle
timeControl method

Max. 9(6-axis articulated robot ＋ additional 3 axes)

Teaching method
Unit for positioning
control
Programming
language
Supported robot

3. Conclusion
T h is ar ticle has i ntroduced the 4 8 V DC compact

2 to 8 ms

2 0 m m sq. AC ser vo motor, 2 4/4 8 V DC EtherCAT

PTP, 3D linear, 3D circularinterface-equipped 4 -axis integrated servo amplifier,

Remote teaching, numeric input

4-axis integrated PB driver, and the 24 VDC high-speed

Arbitrary (pulse, mm, inch, degree)

processing controller SANMOTION C as Servo Systems
products offering value to the “service robot” field, where

Original robot language

advancements have been made in R&D.

Cartesian coordinate robot,
horizontal articulated robot,
vertical articulated robot,
parallel link robot, etc.

to their compact, lightweight, wire-saving, and power-

These products are suitable for “service robots” thankssaving design, their support of multi-axis systems, and theirstandardized power supply voltage allowing everythingfrom the servo motor to the controller to be battery-driven.

(4) Processing performance

SANYO DENKI believes that Servo Systems products with

The high-speed, high-accuracy control of multiple

a common concept can create new value for our customers’

peripheral control devices such as control machinery andequipment and system development as well as contribute tomulti-axis robots is possible with just one controller unit,

the development of high-quality products.

making equipment smaller and faster motion. Moreover,finer and smoother motion of equipment is achieved thanks
to high trajectory accuracy during positional control andsynchronization control of the cam, etc. As a concrete
example of high-speed processing performance, Table 6
shows the control performance when combined with one of
our servo amplifier equipped with an EtherCAT interface isconnected.

47

SANYO DENKI Technical Report No.44 November 2017

Servo Systems Products Offering Value in New Fields

Yasushi Misawa
Joined SANYO DENKI in 1999.
Servo Systems Div., Design Dept. 1
Works on the development and design of servo
motors.

Nobuo Arakawa
Joined SANYO DENKI in 1982.
Servo Systems Div., Design Dept. 2
Works on the development and design ofcontrollers.

Yoshiyuki Murata
Joined SANYO DENKI in 1995.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Masao Mizuguchi
Joined SANYO DENKI in 1998.
Servo Systems Div., Design Dept. 2
Works on the development and design of stepping
drivers.

Yoshihiro Shoji
Joined SANYO DENKI in 2006.
Servo Systems Div., Design Dept. 1
Works on the development and design ofencoders.

SANYO DENKI Technical Report No.44 November 201748

New Products Introduction

Development of the SANMOTION R
3E Model EtherCAT Servo Amplifier
Hiroyuki Kosuge

Naohiro Ito

Tetsuya Hayashi

Noriaki Kasuga

Hideo Miyazawa

Yuki Okabe

Keisuke Ishizaki

Masanao Somemiya

Shuhei Nakazawa

Koichi Machida

1. Introduction
In recent years, industries such as semiconductor

multi-axis type in 2014. The new model has improved its
basic performance for communication and servo control as a
product of the SANMOTION R 3E Model series.

manufacturing equipment, machine tools, industrial robots,and general industrial machinery have seen a rapid adoption
is expanding. Propelled along by factors such as Industry 4.0→ Highof Ethernet for industrial applications and its market share

New model
2017
R 3E
AC inputSingle-axis

Minimum communication cycle /control cycle / speed loop response

and the shift towards IoT, industrial Ethernet is predicted to
In 20 09, SANYO DENKI released the EtherCATequipped SANMOTION R ADVANCED MODEL AC
servo amplifier which is currently being used by a variety ofcustomers. In 2014, we released the new series SANMOTION
R 3E Model AC servo amplifier with improved usability andevolved performance. In 2017, we developed SANMOTION

2012

Performance

expand on a global scale.

62.5 µs / 62.5 µs/ 2,200 Hz

R ADVANCED
Type-H AC input
Single-axis

125 µs / 125 µs / 1,200 Hz

2009

R ADVANCED
Type-K AC input
Single-axis
500 µs / 125 µs / 1,200 Hz

2010

R 3E Model as an EtherCAT servo amplifier with further
improved usability and scalability.
This article briefly introduces the performance andfunctions of this newly developed EtherCAT servo amplifier

2014

R ADVANCED
DC input
Multi-axis

2012

2014

2017
[Year]

Fig. 1: History of the EtherCAT servo amplifierand positioning of the new model

added to the SANMOTION R 3E Model series.

2.2 Appearance and dimensions

2. Product Overview
2.1 The new model and our product lineup

models as typical examples. The standard model is shownon the left, and the safety function-equipped model (Safety)

Fig u re 1 shows the h istor y of SA N YO DEN K I’s

is shown on the right. Figure 3 gives a dimensional drawing

EtherCAT servo amplifier to date. Since developing theof the 200 VAC, 10 A standard model as a typical example.

SA NMOTION R A DVA NCED MODEL EtherCAT

All the new amplifiers have the same dimensions as theservo amplifier in 2009, we have expanded the lineup

SANMOTION R 3E Model analog/pulse input amplifiers

and improved performance by releasing a high-speed

corresponding in terms of the input power and amplifierc om mu n ic at ion t y p e i n 2 01 2 t h at h a s a m i n i mu m

capacity.

communication cycle of 125 μs, and a low-voltage input

49

Figure 2 shows an external view of the 200 VAC, 10 A

SANYO DENKI Technical Report No.44 November 2017

Development of the SANMOTION R 3E Model EtherCAT Servo Amplifier

Table 2 shows t he f u nct ion s a nd c om mu n ic at ion
specifications. While basic EtherCAT functions remaincompatible with existing products, the communication
performance has been improved with the shortened
minimum communication cycle and expanded amount ofdata transfer for data processing. Moreover, the new models
are equipped with a scaling function enabling command
input not only in the conventional encoder pulse unit but
also in linear and rotational units. In addition, the newmodels have passed the latest conformance test, “EtherCAT
Conformance Test Tool Version 2.0” which is the standard
for interoperability of EtherCAT communication.
Standard model

Safety function-equippedmodel (Safety)

Fig. 2: Appearance of the new model (200 VAC/10 A)

Table 1: Main specifications
Power supply
voltage range

Amplifier output
capacity

Functionmodels added to the lineup include nine 200 VAC models,
three 100 VAC models, and three 400 VAC models withamplifier capacity variations.
These amplifiers can drive various servo motors: thebackup absolute encoders and wire-saving pulse encoders.
Also, for use in linear systems or fully-closed loop control
systems, encoders supporting EnDat2.2 (manufactured by

400 VAC25, 50, 100 A

200 VACAmplifierSafetymoduleControlfunction
Mechanicalvibration/
resonance
suppression

STO (Safe Torque Off)STO, SS1, SS2, SLS,
SOS, SSM, SBC• Dual position feedback control• Tandem operation control• FF vibration control (2 levels)• Vibration control for trackcontrol• Adaptive notch filter• Auto tuning response 40 levels
Servo tuning• Servo tuning support function
Start-up,monitoring,
diagnosis

Regarding input power and amplifier capacity, the new

These are compatible with our battery-less and battery-

100 VAC

380 to 480 VAC
10, 20, 30, 50, 75,
100, 150, 300, 600 A
10, 20, 30 A

Compatible encoder

amplifiers.

and direct drive motors.

400 VAC• Absolute encoder(Battery backup, Battery-less)• Wire-saving pulse encoder• EnDat2.2 encoder*developed SANMOTION R 3E Model EtherCAT servo

SANMOTION R series rotary servo motors, linear motors,

100 to 120 VAC

SANMOTION R series motors

Fig. 3: Dimensions (200 VAC, 10 A model)

Table 1 shows the main specifications of the newly

200 to 240 VAC

100 VAC

Compatible motor

Safety function

2.3 Main specifications

200 VAC

Safety standards• Virtual motor operation• Encoder/amplifier temperaturemonitoring• Power consumption monitoring• Drive recorder

UL/cULUL 61800-5-1
Low-voltage
EN 61800-5-1
directive
EMC
EN 61800-3, EN 61326-3-1
directive
FunctionalsafetyISO 13849-1: PL=e
EN 61508: SIL3,
EN 62061: SILCL3

KC mark

KN 61000-6-2, KN 61000-6-4* Not compatible with the safety function-equipped model (Safety)

HEIDENHAIN) can be combined.

SANYO DENKI Technical Report No.44 November 201750

Table 2: Communication specifications
and functions
Interface
Device profile
Synchronization
mode
Communication
cycle
Communication
parameter

EtherCAT
CoE: CANopen over EtherCAT
FoE: Fileaccess over EtherCAT

the motor. This makes it possible to easily monitor a device’s
power consumption.

3.1.3 Virtual motor operation function
As a user assist function aimed at enhancing usability,

DC sync (Sync0, Sync1)

the new model is equipped with a virtual motor operation

SM2 event synchronization

function which simulates operations of the servo motor andMinimum communication cycle:
Position control: 125 µs
Velocity/torque control: 62.5 µs(1/2 of current model but with PDO mapping
limitations)servo amplifier based on commands from a host device,

SDO: Service Data Object

3.1.4 Drive recorder function

PDO: Process Data Object

without actually operating the motor. This function makes it
possible to start up a device safely and swiftly.

To improve troubleshooting, the new model features a

Amount ofdata transfer

Maximum mapping number
Transmitting PDO: 31 objects
Receiving PDO: 31 objects

drive recorder function to record the operational data of theAuthentication
test version

Conformance test (CTT) Ver 2.0

speed, torque, and main circuit DC line voltage. As a result,

PP

Profile Position mode

troubleshooting is made easy as fault cause can be identified

PV

Profile Velocity mode

and appropriate countermeasures can be performed swiftly.

TQ

Torque Profile modeThis helps to improve the reliability of the system.

IP

Interpolated Position mode

HM

Homing mode

CSP

Cyclic Sync. Position mode

The new and current models share the same main

CSV

Cyclic Sync. Velocity mode

communication functions and parameters, making it easier

CST

Cyclic Sync. Torque modefor customers to upgrade to a new model. The following

Operation mode

Function

FT
Touch Probe function
Scaling function(Pulse, mm, degree)

servo motor and amplifier for a set period of time. Such data
recorded during fault occurrences includes motor rotational

3.2 EtherCAT-related functions

functions were expanded to better leverage the advantagesof EtherCAT communication.

3.2.1 Shortening minimum communication
cycle

3. Performance and Main Functions
3.1 Servo performance and functions

By leveraging the strengths of high-speed communication,
we have maximized servo performance and enabled smooth
motion, thus shortening minimum communication cycle

The basic servo performance and functions are the samefrom 125 μs on the current models to 62.5 μs on the new

as the regular SANMOTION R 3E Model series amplifiers.

models. (During speed control and torque control mode)

The main features are as follows.

3.1.1 High-response position speed control

3.2.2 Expanding the maximum amountof data transfer

Feedback response can be improved with a function to

As Figure 4 shows, the maximum amount of data transfer

improve the phase delay within position control and speed

in one communication cycle has increased from 20 objects

control systems, as well as a function to increase integral

on current models to 31 objects on the new models, which

gain. Moreover, with both speed and torque feed-forward

is an increase of around 1.6 times. This has made it possible

compensation, an improvement in command responsivenessto monitor the customer’s device data managed by thecan be expected as well.

servo amplifier with greater speed and in more detail,thus contributing to the IoT trend by providing predictive

3.1.2 Power consumption monitoring
function
The new models feature a power consumption monitoring
function which estimates the power consumption of theservo motor and amplifier based on the speed and current of

51

SANYO DENKI Technical Report No.44 November 2017

maintenance diagnostics of the device and servo equipment.

Development of the SANMOTION R 3E Model EtherCAT Servo Amplifier

4. Conclusion
T h i s a r t i c l e h a s p r e s e n t e d a n ove r v i ew o f t h eperformance, functions, and features of the EtherCAT
servo amplifier that has been newly added to the AC servo
amplifier SANMOTION R 3E Model series lineup.
The new models add a high-speed network type to thehigh-performance, highly-functional SANMOTION R 3E
Model series which pursues safety and usability. We believe
it will greatly contribute to further improving the reliability
and safety of our customers’ devices and help shift towards
IoT.
Moving forward, we plan to enhance functions to further
promote the IoT transition. Moreover, SANYO DENKI
intends to enhance our lineups for DC input, multi-axis
specifications and other network products in order toFig. 4: Comparisonof maximum PDO mapping number

propose products which better satisfy customer needs andcontribute to our customers’ value creation.

3.2.3 Scaling function
The new models feature a scaling function enabling users
to select the unit of measurement used for commands andfeedback data to suit the particular piece of equipment.
Figure 5 illustrates the concept of the scaling function.
Conventionally, host controller would operate by first
converting position commands to encoder pulse units.
However, thanks to the scaling function, it is possible togive position commands for linear motion in mm and forrotational motion in degrees, thus alleviating the burden on
the controller and improving convenience.
Servo amplifier

Controller

Position commands
pulse
degreemm
pulse

degreemm

Fig. 5: Concept of scaling function

英語版用

Condens

英語版用
SANYO DENKI Technical Report
No.44 November 2017

Times Ten

52

Development of the SANMOTION R 3E Model EtherCAT Servo Amplifier

53

Hiroyuki Kosuge

Yuki Okabe

Joined SANYO DENKI in 1987.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Joined SANYO DENKI in 2006.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Naohiro Ito

Keisuke Ishizaki

Joined SANYO DENKI in 1992.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Joined SANYO DENKI in 2008.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Tetsuya Hayashi

Masanao Somemiya

Joined SANYO DENKI in 1999.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Joined SANYO DENKI in 2012.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Noriaki Kasuga

Shuhei Nakazawa

Joined SANYO DENKI in 2007.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Joined SANYO DENKI in 2017.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Hideo Miyazawa

Koichi Machida

Joined SANYO DENKI in 2007.
Servo Systems Div., Design Dept. 2
Works on the development and design of servo
ampliﬁers.

Joined SANYO DENKI in 1994.
SANYO DENKI GERMANY GmbH
Works on the development and design of servo
ampliﬁers.

SANYO DENKI Technical Report No.44 November 2017

New Products Introduction

Development of the SANMOTION R
3E Model Safety Servo Amplifier
Hideki Netsu

Yoshiyuki Murata

Michio Kitahara

Kenichi Fujisawa

Haruhiko Kamijo

Yuuki Nakamura

Yasuhiro Wakui

Mitsuhiro Nishimura

Naoki Kubo

Yoshiki Okada

1. Introduction
In recent years, Europe in particular has establishedinternational safety standards for a variety of industries andequipment, including machine tools, industrial robots, andmedical devices. Such standards place a greater emphasis on“functional safety,” whereby hazards and risks are reduced
to a tolerable level by implementing safety functions using
electrical, electronic, and programmable electronic control
systems. Even in Japan, there is an increasing demand
from the market to support this functional safety standard
primarily in the machine tool and industrial robot industries

Fig. 1: Appearance (10 A)

and this has led to initiatives for even higher safetyfunctions.
C omponents such as ser vo a mpl i f iers adopted i n

2.2 General specifications

equipment which are required to have high safety must

Table 1 provides the general specifications of the 200 VAC

be equipped with the various safety functions defined

input model, while Figure 2 is a structural drawing.

in international standards and obtain safety standard

The new safety functioned servo amplifier (hereinafter

certification.

“new model”), the SANMOTION R 3E Model Safety,

SA N YO DE N K I a l ready of fer s t he w idely-u s e dcan be configured by attaching a special-purpose board

SANMOTION R ADVANCED MODEL and SANMOTION(hereinafter “safety module”) on the side of the existing

R 3E Model which are equipped with STO (Safe Torque Off)SANMOTION R 3E Model analog/pulse train interface or

as a basic safety function. However, in response to the

EtherCAT interface servo amplifier. Moreover, the safety

aforementioned demands, we have expanded our lineup

module and side cover are standardized, so all amplifier

with the addition of the SANMOTION R 3E Model Safety

capacities of each input power specification are compatible

servo amplifier which supports a variety of safety functions.

with the expansion.

This article describes the specifications and features of the
new model.

2. Product Overview
2.1 Appearance
Figure 1 shows the 200 VAC input, analog/pulse traininterface model (left) and the EtherCAT interface model(right).

Table 1: General specifications
Input power
specifications
Amplifier capacity

100, 200, 400 VAC
All capacities

Compatible motor

SANMOTION R series motors

Compatible
encoder

Absolute encoder(for incremental systems, batterybackup, battery-less)Wire saving pulse encoder

User interface

Analog/pulse train interface
EtherCAT interface

SANYO DENKI Technical Report No.44 November 2017

54

The new model is compatible with our standard encoders,
Safety module
Side coverand can be used with the SANMOTION R servo motors.
This means that safety functions can be added by simply
replacing the existing servo amplifier with this new, safetyfunction-equipped model, eliminating the need to makechanges to the servo motor or equipment itself.

3. Functions and Features
Table 2 shows the safety specifications of the new model.
The new model uses software to monitor motor speed andposition to deliver a variety of complex safety functions.

Fig. 2: Structural drawing (10 A model)

Furthermore, it also supports a safety output function
whereby the circuit has a self-diagnosis function.

Table 2: Functional safety specifications
Item

Safety performance
IEC/EN 61800-5-2

EN 61508
IEC/EN 62061

ISO 13849-1: 2015
EN ISO13849-1: 2015

SIL3
SILCL3PL=eCategory 3

Safe Torque Off (STO)
Safety function Safe Stop 1 (SS1)
Safe Stop 2 (SS2)
Safe Operating Stop (SOS)
Safely-Limited Speed (SLS)
Safety output
function

Safe Brake Control (SBC)
Safe Speed Monitor (SSM)
Redundant configuration (SF-CN1, SF-CN2)

Configuration

Safety I/O

Input device

Outputdevice55

No. of inputs

5 points x 2 systems (sink/source)

Mismatch detection time

10 s

Diagnosis cycle

10 minOff-shot pulse width

Less than 1 ms

No. of outputs:

3 points x 2 systems (source)

Diagnosis cycle

10 minSANYO DENKI Technical Report No.44 November 2017

Development of the SANMOTION R 3E Model Safety Servo Amplifier

3.1 Safety functions

3.2 Safety output functions

Table 3 describes the safety functions. The new model isTable 5 provides descriptions of the safety output

equipped with five safety inputs to execute each of these fivefunctions and monitor output functions. The new model

functions. Moreover, parameters can be used to determine

supports two types of safety outputs and three types ofwhich safety function is executed by each safety input.

monitor outputs, which are selectable using parameters.

Table 3: Safety function overview
Safetyfunction
STO

Table 5: Descriptions of the safety output function
and monitor output function

Description
Safely shuts off power supply to the motor.

SS1

Safely reduces motor speed until the motor
stops, then shuts off power supply.

SS2

Safely reduces motor speed until the motor
stops, then monitors stop position.
Monitors the motor stop position, and if thesafe stop range is exceeded, shuts off power
supply to the motor.
Monitors motor speed, and if the safe speed
range is exceeded, shuts off power supply tothe motor.

SOS
SLS

Output function
Safetyoutputfunction

Monitoroutputfunction

Description

SBC

Outputs a signal to control the motor ’s
holding brake.

SSM

Outputs a signal to ensure the motor iswithin a safe speed range.

INM

Outputs a signal to notify the safety
input status.

STA

Outputs a signal to notify the safetyfunction execution status.

STO

Outputs a signal to notify the motor
power shut off status.

Table 4 lists the safety inputs and corresponding selectablesafety functions. Safety inputs SFIA and SFIB support

Table 6 lists safety outputs and the corresponding

all safety functions and the appropriate function can beselectable safety output functions/monitor output functions.

selected to suit the purpose.
SFIC through SFIE function as inputs for Safely-Limited
Speed (SLS). Seven stages of safe speed range (speed limited
levels) can be selected through ON/OFF combinations of
the three inputs. Moreover, for fine-tuned control, SFIA andSFIB can be used to expand the safe speed range up to a
maximum of 31 stages.
With multiple safety inputs and the freedom to selectwhich safety function to execute, the safety functions canbe used flexibly to match the device operating conditions.
It is also possible to execute multiple safety functions

Table 6: Safety outputs and corresponding
selectable safety output functions/monitor output
functions
Safetyoutput
SFOA

Safety output
function
SSM
SBC
−

◯

Monitor output function
INM

STA

STO

◯

◯

◯

SFOB

−

◯

◯

◯

◯

SFOC

◯

◯

◯

◯

◯

○ : Selectable

simultaneously.
Safe Speed Monitor (SSM) can be outputted from SFOC

Table 4: Safety inputs
and selectable safety functions

and, in the same way as Safely-Limited Speed, a maximumof 31 stages of safe speed ranges can be selected throughdifferent combinations of the safety inputs.

Safety function

Safety
input

STO

SS1

SS2

SOS

SLS
(SSM)

SFIA

◯

◯

◯

◯

◯

SFIB

◯

◯

◯

◯

◯

The Safety Input Status Monitor (INM) outputs the

SFIC

−

−

−

−

◯

statuses of safety inputs SFIA and SFIB to SFOA and

SFID

−

−

−

−

◯

SFOB, and the combined statuses of SFIC through SFIE to

SFIE

−

−

−

−

◯

SFOC. This output function enables equipment failures to○ : Selectable

Safe Brake Control (SBC) is a signal for the motor’sholding brake control and can be outputted from all safety
outputs.

be monitored in the path from the safety inputs to the safety
outputs of the servo amplifier circuit.
Moreover, by utilizing the Safety Function Operating
Monitor (STA) and Safe Torque Off (STO) status monitor,

SANYO DENKI Technical Report No.44 November 201756

the new model can monitor consistency between the safety
inputs and servo amplifier internal status, as well as assess

m

im
I1

L1

the amplifier’s status.

im

4. Achieving Required Safety Levels
4.1 Basic structure of safety functions
As Figure 3 shows, the safety module for the new modelcmI2

mutual monitoring function.
The safety input/output circuit has two I/O connectors(SF-CN1, SF-CN2) and all safety I/O signals have beenorganized into two systems. As such, when the user executesa safety function, there is a need to simultaneously control
both safety input signal systems and this new model can

L2
im

duplicates the “input devices,” “logic,” and “output devices”
and uses a Cat. 3 (ISO 13849-1) configuration which has a

O1

imInternal connectioncMutual monitoring

I 1, I 2

Input unit

L 1, L 2

Logicm

Monitoring

O 1, O 2

Output unit

O2
imFig. 3: Basic configuration

detect a failure if there is a logic mismatch between the twosystems. Moreover, the safety I/O circuit has a self-diagnosis
function and regularly monitors circuit failures.
The safety module has duplicated voltage generatingWith a Cat. 3 configuration, the encoder is also included

circuit and it is equipped with a self-diagnosis function.

as an input device. As such, the encoders should have

Hazardous movements of equipment are avoided bybeen made redundant and able to detect encoder failures

regularly monitoring mutual voltage faults (excessivefrom the positional information of these encoders. Or,

voltage, low-voltage), shutting off the power supply to a

the encoder adopted should have obtained functional

system if a fault has been detected and transferring into asafety certification and be able to detect failures from thesafe state (in the case of SANYO DENKI, a Safe Torque Off

encoder’s self-diagnosis. However, these methods would

state).

require significant changes to the equipment configuration,

The major components that make up the logic unit havethus increase the customer’s burden.

also been duplicated and equipped with a self-diagnosis

As such, SANYO DENKI has newly developed andfunction. The main diagnosis functions are shown below.

embedded a diagnosis function in the safety module for•

Processor diagnosis

the new model that regularly detects encoder failures. As a•Memory diagnosis

result, a high-level safety function has been achieved simply•

Clock diagnosis

with our standard encoder, which has not obtained any•

Program mutual monitoring, etc.

functional safety certification.

As shown above, by duplicating all circuits and equippingthem with a self-diagnosis feature, the safety function is not
lost and safety can be maintained when a failure occurs on
single system.

57

4.2 Encoder diagnosis

SANYO DENKI Technical Report No.44 November 2017

Development of the SANMOTION R 3E Model Safety Servo Amplifier

4.3 Parameter settings
The safety module has parameters specifically for safety

5. Conclusion

functions (hereinafter “safety parameters”) separate

This article has presented an overview and features of thefrom the servo amplifier. Just as servo parameters, safety

SANMOTION R 3E Model Safety servo amplifier that has

parameters can be edited using our setup program, thebeen newly added to the AC servo amplifier SANMOTIONSA NMOTION MOTOR SETUP tool. The following

R 3E Model lineup.

special-purpose functions have been added for safety(1) Features five safety functions to suit the specificparameters.

application of equipment, including “decelerating•

Requires a password to authorize parameter changing.

and stopping the motor safely then shutting off motor•

Displays final confirmation notification at parameter

power” and “monitoring the motor to ensure rotation at

updating.
••

Displays “power re-boot” notification after parameterchanges.

of five safety inputs for Safely-Limited Speed and Safe

Records history of additional information such as when

Speed Monitor.

parameters were changed and which tool versions were•a safe speed.”(2) Enables selection of up to 31 stages by using a maximum(3) Equipped not only with the safety output functions ofused.

Safe Brake Control and Safe Speed Monitor, but alsoP rohibits input of values if parameter changing has notthree types of status monitoring output functions so thatbeen authorized.

the equipment can monitor the servo amplifier to ensure

The above special-purpose functions prevent unintended
parameter changes and secure parameter safety.

operation of safety functions.
(4) By developing a new encoder failure diagnosis function,
we have realized safety functions with one of the

4.4 Safety level
By adopting the above-described redundant configuration
with self-diagnosis and mutual monitoring in addition to aindustry’s highest safety levels, and by combining the
new model with our standard SANMOTION R series
servo motors and encoders.

diagnosis function for the encoder, the new model achieves

We believe this new model will greatly contribute to

SIL3 for EN 61508, SILCL3 for IEC 62061, and PL=eenhancing equipment safety and obtaining functional safety

for ISO 13849-1 which is the highest level of safety in thecertification.

industry (as of April 2017 according to SANYO DENKI’s

Moving forward, SANYO DENKI wishes to continue

investigation) even when combined with a standard encoder.

development of products that can contribute to the creationof safety systems by our customers with our focus on
obtaining both communication and safety certification andenhancing safety levels.

SANYO DENKI Technical Report No.44 November 201758

Development of the SANMOTION R 3E Model Safety Servo Amplifier59

Hideki Netsu

Yuuki Nakamura

Joined SANYO DENKI in 1989.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Joined SANYO DENKI in 2010.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Yoshiyuki Murata

Yasuhiro Wakui

Joined SANYO DENKI in 1995.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Joined SANYO DENKI in 2012.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Michio Kitahara

Mitsuhiro Nishimura

Joined SANYO DENKI in 1991.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Joined SANYO DENKI in 2014.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Kenichi Fujisawa

Naoki Kubo

Joined SANYO DENKI in 1992.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Joined SANYO DENKI in 2015.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Haruhiko Kamijyo

Yoshiki Okada

Joined SANYO DENKI in 2005.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

Joined SANYO DENKI in 2015.
Servo Systems Div., Design Dept. 2
Works on the design and development of servo
ampliﬁers.

SANYO DENKI Technical Report No.44 November 2017

44

November
2017

https://www.sanyodenki.com

Published in Japan in November 15, 2017 by SANYO DENKI CO., LTD.
Published semi-yearly
3-33-1 Minami-Otsuka, Toshima-ku, Tokyo 170-8451, Japan
Phone +81 3 5927 1020
Publisher Shigeo Yamamoto
Editorial Board Members:
Nobumasa Kodama
Editor-in-Chief
Satoru Onodera
Managing Editor
Akira Tsukada
Managing Secretary
Shiho Tsukada
Secretary
Yukari Kitazawa
Masafumi Yokota
Masakazu Uchida
Kiyoshi Mizuguchi
Hideki Netsu
Daigo Kuraishi
Hiroshi Miyazaki
Copyright © 2017 SANYO DENKI CO., LTD.
All rights reserved.
No part of this publication may be reproduced in any manner whatsoever without written
permission from SANYO DENKI.
All company and product names used in this publication are trademarks or registeredtrademarks of their respective companies.